Billet Kicker Cover Instructions
Contents
1. KS st gt gt x p x e vi f E x pe gt E x e N E E x N E FIGURE 4 PAGE 10 INCLUDED PARTS DETAIL CABLE STYLE COVER V4 101613 BAKER BILLET KICKER COVER KIT BILLET CABLE STYLE COVER KIT INCLUDED PARTS DETAIL FIGURE 4 OTY PN 25C50KLHS 584 56P 583 GAS WT3096 987687 3094 DSSC WT3196 10705 01149 TWCA11 TC411 7078 2418 14 292032 290227 33430 56 7073 33560 56 292014 2213 290225 33350 56 7071 6N4 SIDE 578 56MP 51740 001 6100 31C125KCSS P 639K269 750x1 250x 250ADL AS2035 33096 54 291222 292013 _ sch DESCRIPTION 1 4 20 Low Head Cap Screw Cover Ball and Ramp Gasket Ball and Ramp Inner Ramp Actuator 3 8 Ball Bearing Actuator Actuator Ferrule Outer Ramp Actuator E Clip Release Rod Washer Actuator Rod Thrust Bearing Actuator Rod 1970 E84 Release Rod Buna 116 Fill Cap Spring Starter Gear Starter Gear Nut Crank Gear Starter Clutch Lock Tab Crank Gear Key Starter Clutch Lock Washer Starter Clutch Crank Gear Nut Starter Clutch Gasket Kicker Cover Cover Cable Style Level Plug 3 8 24 Zero Leak Washer 5 16 AN 5 16 18 x 1 4 SHCS S S Polished Bronze Bushing Seal Crank Gear Shaft Washer Crank Gear Shaft Shaft Crank Gear Return Spring Kicker Shaft Stud Return Spring Release Rod For 1970 E84 Models See Page 17 For 1936 69 Models Late 19842. 8 FIGURE 7 BENDING TAB OVER FIGURE 8 SHOWN WITH TAB BENT OVER CONTINUED ON NEXT PAGE PAGE 13 COVER PREP INSTRUCTIONS V4 101613 BAKER BILLET KICKER COVER KIT IT IS CRITICAL THAT CARE IS TAKEN WHEN BENDING OVER WASHER EXCESSIVE HAMMERING COULD CAUSE DAMAGE TO THE MAIN SHAFT OR BEARINGS 4 Install the supplied side cover gasket on the transmission at this time 4a MECHANICAL COVERS Place the stock clutch actuator rod assembly into the hole in the end of the mainshaft on the right side of the bike in preparation for side cover installation For early 4 Speed Transmissions with large clutch release bearing install bearing into kicker cover at this time making sure that the bearing is aligned with the fork Figure 9 4b FOR HYDRAULIC CABLE TYPE COVERS Place the provide BAKER release rod assembly in the end of the mainshaft on the right side of the bike in preparation for side cover installation Release Rod is for 1970 E84 Models if you have a 1936 69 Model see page 17 Late 1984 Later Models use stock style 3pc rod setup 5 Using the provided fasteners and washers or the stock transmission cover nuts Install the BAKER Premium Kicker Cover using care aligning the gear teeth together Cover should fit flush with out any tension Torque the side cover down to 190 220 in Ibs 17 23 4 1 Nm using Blue Thread Lock while referring to the torque sequence diagram Figure 10 6 CABLE STYLE C
3. Later Must Use Stock Style 3pc Rod PAGE 11 INCLUDED PARTS DETAIL HYDRAULIC LEGEND V4 101613 BAKER BILLET KICKER COVER KIT DISSASSEMBLY 1 FOR YOUR SAFETY DISCONNECT BOTH BATTERY CABLES FAILURE TO DUE SO COULD RESULT IN PERSONAL INJURY 2 With your bike securely supported on a bike lift or jack drain the transmission fluid Refer to your Factory Service Manual for location of your drain plug 3 Depending on the style of exhaust that you have on your motorcycle the exhaust may need to be removed at this time as well to allow access to the transmission side cover Remove the stock side cover as well as the factory clutch actuator rod and set aside 3a FOR HYDRAULIC COVERS While referencing the Factory Service manual remove the clutch cable cable style clutch lever and set aside 4 Remove the derby cover and back off the jam nut for the clutch adjustment 5 Remove the starter clutch gear and spring following the procedures listed in your Factory Service Manual Starter Clutch Puller H D P N 95650 42 or equivalent is necessary for removal 6 Take the time to wipe down the gasket surface of the bearing door and inspect to make sure it is free of residual oil old gasket material and debris THE REMOVAL OF THE OIL DEFLECTOR ON EARLY STYLE 4 SPEED lt A TRANSMISSIONS IN NECESSARY FOR PROPER FITMENT OF THE HYDRAULIC KICKER COVER IF REMOVING THE STUDS TO USE THE BOLTS SUPPLIED CHASE THREADS WITH A 5 16 18 TAP US
4. 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 Ml 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 or up to 24 000 miles whichever is sooner 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 BAKER In the event warranty service is required the original purchaser must call or write BAKER M immediately with the problem If it is deemed necessary 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 M option repair or replace the defective part o
5. HP Hydraulic Kicker Cover 29 1 24181141 Buna 116 30 1 292032 Fill Cap Release Rod For 1970 E84 Models See Page 17 For 1936 69 Models Late 1984 Later Must Use Stock Style 3pc Rod PAGE 7 INCLUDED PARTS DETAIL HYDRAULIC LEGEND V4 101613 BAKER BILLET KICKER COVER EXPLODED VIEW INCLUDED PARTS DETAIL MECHANICAL COVER FIGURE 3 PAGE 8 INCLUDED PARTS DETAIL MECHANICAL COVER BAKER BILLET KICKER EXPLODED VIEW BILLET MECHANICAL COVER KIT INCLUDED PARTS DETAIL FIGURE 3 PN 291222 33096 54 31C125KCSS P 292013 292016 750x1 250x 250ADL 51740 001 6100 292032 24181141 478 56MP 37074 38C 66808 476 56 3 070 39B 6443HW 6391K183 68077 6N4 SIDE 290227 7073 292014 33430 56 33350 56 33560 56 2213 290225 7071 639K269 V4 101613 DESCRIPTION Return Spring Kicker Shaft Shaft Crank Gear 5 16 18 x 1 4 SHCS S S Polished Stud Return Spring Washer Crank Gear Shaft Seal Crank Gear Shaft Level Plug 3 8 24 Zero Leak Washer 5 16 AN Fill Cap Buna 116 Mechanical Kicker Cover Release Shaft O Ring Release Shaft Release Shaft Housing Lever Release Shaft Washer Release Shaft Bushing Release Shaft E Clip Release Shaft Gasket Side Cover Spring Starter Gear Nut Crank Gear Washer Crank Gear Starter Gear Crank Gear Starter Clutch Key Starter Clutch Washer Starter Clutch Nut Starter Clutch Bronze Bushing PAGE 9 INCLUDED PARTS DETAIL MECHANICAL LEGEND
6. ING CAUTION NOT TO DAMAGE THE THREADS IN YOUR CASE KICKER COVER PREPERATION USE CAUTION WHEN ASSEMBLING SO THAT YOU DO NOT DAMAGE THE COVER AND OR ITS COMPONENTS 1 Referring to the exploded view Figure 1 2 3 or 4 apply a little lube in the side cover within the kicker shaft bore and on the shaft seal 2 Install the kicker shaft washer onto the kicker shaft with the inside of the washer chamfer facing toward the threaded end of the shaft Figure 5 3 Apply some transmission oil on the kicker shaft and install it FIGURE 5 through the side cover NOTE CHAMFER FACING THREADED END ALIGNMENT OF SHAFT TO CRANK GEAR IS NESSESSARY FOR PROPER OPERATION SEE FIGURE 6 FAILURE TO DUE SO COULD RESULT IN DAMAGE TO COVER ASSEMBLY KICKER GEARS AND OR PERSONAL INJURY THE BOTTOM DASHED LINE IS FOR THE CABLE STYLE COVER 473 56CP K ALIGNMENT ONLY 4 Install the BAKER crank gear onto the shaft with supplied crank gear washer and crank gear nut using BLUE thread lock Torque to 30 ft Ibs 5 Bend over the lock tabs on the crank gear washer to secure the crank gear nut CONTINUED ON NEXT PAGE PAGE 12 COVER PREP V4 101613 BAKER BILLET KICKER COVER KIT 6a FOR HYDRAULIC COVERS Remove the hydraulic piston from the side cover The best way is to use the light touch of an air blow gun in the hydraulic feed port It should be noted that you should have the side cover back side down on a couple of towels on the
7. OVERS Remove the six fasteners holding on the ball and ramp cover remove the ball and ramp cover and gasket 6a 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 6b 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 DSSC and seat the cable figure 11 6c Install the ball and ramp assembly with outer ramps tab in the 2 o clock position figure 12 INSTALLING FFRRUI ON CARI F FIGURE 11 6d Place the ball and ramp cover plate with gasket back into position Using Blue thread lock install the six bolts Torque the six 1 4 20 x 1 2 PN 25C50KLHS to 7 9 ft lbs 84 108 in Ibs 7 Install the kick arm return spring using care turning it clockwise spring will be under pressure when installing until it s locked onto the return spring stud figure 13 CONTINUED ON NEXT PAGE PAGE 14 INSTALLATION V4 101613 BAKER BILLET KICKER COVER KIT 8 MECHANICAL COVERS Install your factory stock T release arm and kick arm pedal following your Factory Service Manual Adjust your clutch per Factory Service Manual HYDRAULIC COVERS FOR MECHANICAL CABLE STYLE COVER PROCEED TO FINISH LINE PAGE 16 1 Bolt to the handlebars the 11 16 bore clutch lever assembly of your choice Run the AN 3 brake line
8. R KIT 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 PAGE 19 DISCLAIMER
9. Starter Gear Gasket Kicker Cover Spring Starter Gear Release Rod For 1970 E84 Models See Page 17 For 1936 69 Models Late 1984 Later Must Use Stock Style 3pc Rod PAGE 5 INCLUDED PARTS DETAIL FF HYDRAULIC LEGEND V4 101613 BAKER BILLET KICKER EXPLODED VIEW INCLUDED PARTS DETAIL HYDRAULIC COVER FIGURE 2 PAGE 6 INCLUDED PARTS DETAIL HYDRAULIC COVER V4 101613 BAKER BILLET KICKER COVER EXPLODED VIEW BILLET HYDRAULIC COVER KIT INCLUDED PARTS DETAIL FIGURE 2 ITEM OTY PN DESCRIPTION 1 1 6N4 SIDE Gasket Side Cover 2 7078 1970 E84 Release Rod 3 1 290227 Spring Starter Gear 4 1 45 9404 Bleeder Screw 5 1 33430 56 Starter Gear 6 1 33560 56 Starter Clutch 7 1 2213 Key Starter Clutch 8 1 290225 Lock Washer Starter Clutch 9 1 7071 Nut Starter Clutch 10 1 7073 Nut Crank Gear 11 1 292014 Lock Tab Crank Gear 12 2 BD411 56 Thrust Washer 13 1 FNT 1024 Bearing Heavy Duty Needle 14 1 BD410 56 Spacer Bearing 15 1 10705 01149 E Clip Release Rod 16 2 66855 O Ring Hyd Piston 17 1 124 56LD Hyd Piston 1 5 DIA 18 1 639K269 Bronze Bushing 19 1 33350 56 Crank Gear 20 1 291222 Return Spring Kicker Shaft 21 1 292013 Stud Return Spring 22 1 33096 54 Shaft Crank Gear 23 9 31C125KCSS P 5 16 18 x 1 SHCS S S Polished 24 1 292016 Washer Crank Gear Shaft 25 9 6100 Washer 5 16 AN 26 1 750x1 250x 250ADL Seal Crank Gear Shaft 27 1 51740 001 Level Plug 3 8 24 Zero Leak 28 1 478 56
10. V4 101613 BAKER BILLET KICKER COVER KIT P N 478 56 MECHANICAL BILLET KICKER COVER 478 56HP K HYDRAULIC BILLET KICKER COVER 478 56CP K CABLE STYLE BILLET KICKER COVER 479 56P K FF HYDRAULIC BILLET KICKER COVER EF stands for Function Formed PAGE 1 COVER V4 101613 BAKER BILLET KICKER COVER KIT OVERVIEW FEATURES The new Premium BAKER Billet Kicker Covers is yet another part that we added to the ever growing BAKER product line These show polished gems are made out of Billet 6061 T6 for added strength and increased part life Stainless Steel T303 release shaft housing with O Ring mechanical version only keeping that fluid inside the transmission no more leaking shafts our renowned strong and smooth BAKER Klassic Kicker Gears and solid one piece kicker shaft for those guys who just kick the shit out of their bike FITMENT e BAKER 6N4 Transmission e 4 Speed 1936 1986 FL FX Models The BAKER Billet Mechanical Kicker Cover is the most historical requires the use of a clutch release arm 1936 1986 Knucklehead Panhead Shovelhead Motors The BAKER Billet Hydraulic Kicker Cover is designed to work with an 11 16 Bore Diameter Hydraulic Clutch Lever This is the size of the Factory Clutch Lever and the most common size of aftermarket Clutch Levers The BAKER Billet Cable Type Kicker Cover is designed to work with O E type clutch cables from 1990 2006 and includes ball ramp actuation component
11. down to the side cover and bolt it in place with a 3 8 24 Thread Banjo Bolt Torque Banjo Bolt to 17 22 ft Ibs 23 30 Nm TAKE THE NENECESSARY TIME AND eo PROPER PRECAUTIONS TO ROUTE THE HYDRAULIC LINE AWAY FROM MOVING PARTS AND ANY EXHAUST PIPES THAT COULD DAMAGE THE LINE IN ANY WAY MAKE SURE THAT YOU ARE ABLE MOVE THE FRONT END THROUGH ITS FULL RANGE OF MOTION LEFT N SC TO RIGHT WITHOUT BINDING KINKING OR Ko J PINCHING THE HYDRAULIC LINE FAILURE TO gt l DO SO COULD RESULT IN PARTFAILURE OR SHOWN W SPRING AND NEN FIGURE 13 PERSONAL INJURY BLEEDING THE HYDRAULIC CLUTCH SYSTEM BAKER DRIVETRAIN MAKES THE STRONG RECOMMENDATION THAT A POWER BLEEDER SYSTEM BE UTILIZED WHETHER THAT IS A HAND OPERATED PUMP OR PNEUMATIC TO BLEED THE HYDRAULIC CLUTCH SYSTEM ON YOUR MOTORCYCLE IT IS THE MOST EFFECTIVE AND ONLY SUREFIRE WAY TO ENSURE THAT ALL OF THE AIR BUBBLES ARE PURGED FROM THE SYSTEM IF YOU DO NOT OWN A POWER BLEEDER THE FOLLOWING SET OF INSTRUCTIONS WILL ENABLE YOU TO BLEED YOUR CLUTCH SYSTEM GREAT CARE AND ATTENTIONS NEEDS TO USED IN FOLLOWING THESE STEPS TO ENSURE A PROPERLY BLED AND FUCNTIONING SYSTEM TO ENSURE YOUR SAFETY AS A RIDER 1 Before you can bleed the Hydraulic Clutch system you need to adjust the free play and rod length at the clutch Using an Allen wrench run the adjuster bolt center of the clutch inboard until it can be felt to bottom the piston out in the side cover You will al
12. f 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 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 18 TERMS V4 101613 BAKER BILLET KICKER COVE
13. nstallation Continued Bleeding Hydraulic System 16 Bleeding Hydraulic System Continued Finish Line 17 Release Rod for 1936 69 Models 18 Terms 19 Disclaimer PAGE 3 TABLE OF CONTENTS V4 101613 BAKER BILLET KICKER EXPLODED VIEW FIGURE 1 PAGE 4 INCLUDED PARTS DETAIL FF HYDRAULIC COVER V4 101613 BAKER BILLET KICKER EXPLODED VIEW BILLET FUNCTION FORMED HYDRAULIC COVER KIT INCLUDED PARTS DETAIL FIGURE 1 ITEM CON DO W DH ND NO DDR DR P P Pp Pp po HAH H SH SH SH SH S sch O O On PS GO O AN OO BPW O OTY PN 291222 33096 54 292013 51740 001 45 9404 292016 31C125KCSS P 790X1 250X 250ADL 479 56P 66827 130 56FP 66855 124 56LD 6391K269 10 05 01149 BD411 56 FNT 1024 BD410 56 7078 33350 56 292014 7073 7071 290225 2213 33560 56 33430 56 6N4 SIDE 290227 sch sch esch sch sch sch n sch DESCRIPTION Return Spring Kicker Shaft Stud Return Spring Zero Leak Drain Plug Bleeder Screw Washer Kicker Shaft 5 16 18 X 1 4 Polished SHCS Seal Kicker Shaft FF Hyd Kicker Cover O Ring Fill Cap Fill Plug O Ring Hyd Piston Hyd Piston 1 5 DIA Bronze Bushing 2 Long E Clip Release Rod Thrust Washer Bearing Heavy Duty Needle Spacer Bearing 1970 E84 Release Rod Crank Gear Lock Tab Crank Gear Nut Crank Gear Nut Starter Gear Lock Washer Starter Gear Key Starter Gear Starter Clutch Gear
14. off wheel chop box or equivalent e Belt sander bench grinder or file e Torch or map gas e Small container of oil 3 Using figure 15 cut the supplied rod to desired length example 1965 69 models cut off 0 315 8 00MM or 1936 64 models cut off 0 575 14 60MM All measurements are within 0 010 0 25MM 4 After the release rod has been cut to desired length put a chamfer on the end to break the sharp edge this will CHAMFER ADDED FIGURE 16 also to ease in the installation of the rod Chamfer l could be added using a bench grinder belt sander or a file Figure 16 HARDEN THE END OF THE RELEASE e SHAFT AFTER MODIFICATION THIS WILL STRENGTHEN THE END SO THAT PREMATURE FAILURE DOES NOT OCCUR 5 USE CAUTION AND BE CAREFUL NOT TO BURN YOURSELF DURING THIS PROCESS Using a torch or preferably map gas heat the end of the TORCH AND IMMERSE ROD NOIL FIGURE 17 rod until it starts to glow red heat about 1 000 25 4MM of the rod end making sure to heat the rod evenly Once the rod is red cherry quickly quench immerse the hot end in an oil bath Figure 17 6 Let the rod cool then clean the end using a Scotch Brite pad or sand paper Proceed back to page 14 for the rest of the installation PAGE 17 RELEASE ROD MODIFICATION V4 101613 BAKER BILLET KICKER COVER KIT SPECIALORDERS A minimum 500 deposit is required with all special orders Special orders include unique case finishes
15. r fill plug and level plugs Re install the exhaust if removed and double check that all fasteners are tight on the motorcycle any ancillary parts that you removed to perform this installation are back in their intended place on the motorcycle Once the maiden voyage had been made around the block or down the road Take the time to double check all fasteners and hydraulic fittings for tightness Also with the bike as close to level as you can safely get it and the transmission fluid warmed up double check the level of the fluid using a 3 16 Allen to remove the oil level plug Drain off any excess fluid if the transmission is overly full Level should be at the bottom of the hole Re install the oil level plug with snug You are complete SHOWN INSTALLED WITH KICK ARMAND PEDAL FIGURE 14 PAGE 16 BLEEDING THE HYDRAULIC SYSTEM FINISH LINE V4 101613 BAKER BILLET KICKER COVER KIT RELEASE ROD MODIFICATION BAKER SUPPLIES A 1970 E84 CLUTCH RELEASE IF YOU HAVE A 1936 gt 69 MODEL MODIFICATION TO THE ROD LENGTH IS NECESSARY FOR YOUR CLUTCH TO FUNCTION PROPERLY 1 Refer to the figure below for your desired release rod length per model year 14 125 358 77MM OVERALL d in BAKER SUPPLIED RELEASE ROD 19 0 E84 TAPERED MAINSHAFT 13 810 350 77MM OVERALL 1965 69 TAPERED MAINSHAFT 13 550 344 17MM OVERALL 1936 64 TAPERED MAINSHAFT FIGURE 15 2 Tools required to modify parts e Cut
16. re any fluid begins to flow out of the clear tubing 6 Squeeze the clutch lever and hold it against the handlebar to build up hydraulic pressure Open the bleeder valve on the side cover about turn Clutch fluid will flow through the clear tubing Close the bleeder when the clutch lever has traveled about 50 75 of its full travel Wait for the clutch lever to return to its released position Repeat step 6 as necessary until all air bubbles have been forced out of the system and there is no bubbles in the fluid within the clear tubing 7 When the system has been fully bled and the clutch lever no longer feels mushy fully tighten the bleeder valve on the side cover to 80 in Ibs It may be necessary to fill the fluid in the reservoir to the full line at this time DO NOT OVERFILL THE MASTER CYLINDER 8 Place the cover back on the master cylinder and tighten down according to the control manufacturer s specifications Check to make sure that the clutch line is tight at the clutch lever and the side cover at this time 9 Replace the derby cover on the primary referring to the Factory Service Manual for the proper tightening sequence FINISH LINE 1 Remove the fluid level plug on your new kicker cover Remove your fill plug fill your transmission until the fluid starts to weep out the level hole Fluid capacity is about 20 24fl oz BAKER Recommends Spectro M Heavy Duty Platinum 6 Speed Transmission Oil P N H HDPG6 2 Re install you
17. s TOOLS RESOURCES REQUIRED PARTS e Factory Service Manual For Your Motorcycle e Factory Parts Manual For Your Motorcycle e Common Hand Tools allens sockets hammer chisel e Torque Wrench with ft lbs and in Ibs e Blue Loctite 242 Removable or Equivalent e Red Loctite 271 Permanente or Equivalent e Starter Clutch Puller H D P N 95650 42 or equivalent e Transmission Fluid BAKER Recommends Spectro M Heavy Duty Platinum 6 Speed Transmission Oil P N R HDPG6 THESE ADDITIONAL ITEMS ARE NEEDED FOR THE HYDRAULIC KICKER COVERS PN 478 56HP K amp PN 479 56P K e 10MM Banjo Fittings e Hydraulic Line e Hydraulic Fluid We Recommend H D DOT 5 Brake Fluid P N 99902 77 e Loctite Thread Sealant 567 available at your local auto parts store e Hydraulic Master Cylinder with an 11 16 Bore PAGE 2 OVERVIEW V4 101613 BAKER BILLET KICKER COVER KIT TABLE OF CONTENTS 2 Overview 3 Table Of Contents 4 Included Parts Breakdown FF Hydraulic Cover 5 Included Parts Breakdown FF Hydraulic Cover Legend 6 Included Parts Breakdown Hydraulic Cover 7 Included Parts Breakdown Hydraulic Cover Legend 8 Included Parts Breakdown Mechanical Cover 9 Included Parts Breakdown Mechanical Cover Legend 10 Included Parts Breakdown Cable Style Cover 11 Included Parts Breakdown Cable Style Cover Legend 12 Cover Preparation 13 Cover Preparation Continued Installation 14 Installation Continued 15 I
18. so know that you have hit the bottom point as the clutch will begin the move At the point where it is fully bottomed out back the adjuster off to 1 full turn The closer to the 1 full turn point that you adjust it too the more reserve you will have in the lever before the motorcycle begins to move with the full engagement of the clutch being proportionally closer to the end of the sweep of the lever This amount can be adjusted to rider comfort and riding style Tighten the jam nut to 120 in Ibs while holding the adjuster screw from rotating CONTINUED ON NEXT PAGE PAGE 15 INSTALLATION BLEEDING OF THE HYDRAULIC SYSTEM V4 101613 BAKER BILLET KICKER COVER KIT 2 Place a clear tube over the bleeder valve on the side cover and run it into a clean container 3 Stand the motorcycle upright so that the master cylinder on the clutch lever is level Remove the master cylinder lid and gasket 4 Add new DOT 5 Silicone Brake Fluid to the master cylinder reservoir under to the fluid level is at or below the full line DO NOT OVERFILL THE MASTER CYLINDER 5 Squeeze the lever 5 10 times Open the bleeder valve on the side cover and clutch fluid should flow through the tubing If not keep pumping the lever as it may take a few minutes for the fluid to make it all of the way through the line and cover Once fluid begins to flow through the clear tube close the bleeder valve It may be necessary to add more fluid during this time even befo
19. work bench when doing this as the piston will shoot out When you have the piston out give it a bath of H D DOT 5 Brake Fluid making sure to fully coat the o rings in the brake fluid BOTTOM IS FOR CABLE 6b Double check that the inside of the St VER ONLY hydraulic bore is free of debris and dirt Also check the entire inside surface of the side cover ALIGN GEAR BOSS WITH KEYWAY IN SHAFT FIGURE 6 to eliminate introducing dirt or packing material into your transmission With the inside of the part checked and determined to be clean coat the inside walls of the hydraulic bore with the same H D DOT 5 Brake Fluid used to lubricate the o rings THESE EXTRA STEPS OF LUBRICATION MAKE A VERY DRAMATIC 2 lt DIFFERENCE THE WEAR LIFE OF THE SEALING O RINGS YOUR BAKER PREMIUM HYDRAULIC KICKER COVER AND ARE NECESSARY FOR CORRECT PART FUNCTION 6c Using a gentle touch slide the piston back in the side cover until it bottoms out Take care to not force the piston into place in such a way that o ring damage could occur on the edge or opening of the Hydraulic Bore INSTALLATION 1 Install the supplied BAKER ratchet gear spring gear hub key washer and nut with blue thread lock refer to exploded views 2 Torque the ratchet hub nut to 50 60 ft Ibs 3 Make sure the ratchet gear slides freely in and out with no binding Bend the washer over the nut so it locks it into place using a mallet and chisel tip Figure 7
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