F6R - Bad Hog
Contents
1. ee 10 Screw toggle switch to ground point FIGURE 23 FIGURE 24 2 With the Toggle Switch taken care of you now need to route the main wire GU Long Blade Terminal to the front of the bike from the Reverse Side Cover up to the Fairing There are 3 ways to accomplish this from easy to difficult Route the wire behind the starter through the Battery Box and then under the Gas Tank Dash coming out under the Fairing on the Right side of the neck Loosen the Gas Tank and tip it up in the back and route the wire under the Gas Tank up to the Fairing in the same position or as we did on our BAKER R amp D Bagger under the gas tank in the Factory plastic wire housing up to the Fairing No matter which method you choose care needs to be taken to ensure that the wires are not getting crimped chaffed rubbed or melted by running them in a safe manner With the wire successfully run to the front of the bike you can plug the Female Blade Terminal into the back of the Toggle Switch Grab the ground wire for the Toggle Switch 18 long plug the blade Terminal into the back of the Toggle Switch use the eyelet end to go under the 10 screw holding the large wire clamp on the right side of the neck to act as the frame ground point Use a couple of zip ties to secure the wires within the inside of the Fairing as well as the main wire when it passes by the neck Re Install the Outer Fairing following the Factory Service Manual PAGE 18 ASSEMBLY V9 51502. PREMIUM DRIVETRAIN INNOVATIONS FOR AMERICAN MOTORCYCLES INSTALLATION INSTRUCTIONS V9 51508 GETTING STARTED TOOLS FEATURES OVERVIEW In our plight for Drivetrain perfection we have come out with another innovation to make the riding experience on your American motorcycle the pleasure it should be We are proud to announce the re lease of the BAKER Reverse Kit F6R for short The BAKER Reverse system is unlike any other on the market in that it works off the stock foot shifter lever With the simple hit of the Reverse Safety Toggle Switch and a flick of your foot you are in Reverse It is that simple No reaching near hot pipes to put a bike in Reverse anymore The BAKER Reverse system is designed so that it is impossible to get a bike locked in 1st and Reverse like on some other models out there Additionally the Reverse Gears are all fully heat treated diamond ground gear grade 8620 steel The BAKER Reverse shift drum also improves greatly over the ability to find neutral than stock With an overall 4 98 1 gear ratio in Reverse 45 shorter than the stock 3 34 1 first gear it is essentially a creeper gear There are also no problems with stock exhaust clearance Also compatible with our previously release F6F kit FITMENT 2006 2008 Dyna s 2007 2008 Softails amp FLT FLH Models GETTING STARTED The BAKER F6R System is designed in such a manner that any competent mechanic or dealership that is familiar with the new H D Cruise D
3. 6 91665A350 Spiral Snap Ring 7 16 Shaft 1 7 12R50PRPOP 1 8 x 1 2 Split Roll Pin 1 8 409 RVO7 Reverse Safety Lever 1 9 25R100PDP 1 4 x 1 Pull Dowel 1 10 410 RV07 Reverse Side Cover Hydrualic 1 11 HK1412 Split Idler Gear Bearing 2 12 94 4508 Bleeder Valve 1 13 37084 84L Clutch Rod Assy Hydraulic 2 815 Overall 1 14 124 56L Hydraulic Piston 1 500 Dia LSD 1 15 66855 Hydrualic Piston O Ring 1 1 4 x 1 1 2 x 1 8 2 PAGE 6 INCLUDED PARTS DETAIL V9 51508 Ke BAKER F6R DISASSEMBLY DISASSEMBLY Whereas it may seem as 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 instructions Softails Dyna s and FLT FLH s are all different configurations and require a different order and method to accomplish the various steps lf you are in the process of installing a Lehman Trike Conversion wait until after you complete the BAKER F6R installation to remove the rear wheel swingarm and rear brake SIMILAR TO ANY OTHER DRIVETRAIN RELATED PROJECT THE FIRST STEPS THAT YOU WANT TO TAKE ARE TO REMOVE THE SEAT AND DISCONNECT THE BATTERY FOR YOUR OWN SAFETY Now is a good time to get out a couple of drain pans and drain the primary fluid as well as the transmission fluid For location of the applicable drain plugs check your Factory Service Manual Next remove the sadd
4. Do not bolt in the right rear bolt on the top cover at this time you need to thread it in later when you install the Reverse Solenoid Wiring Harness PAGE 13 ASSEMBLY V9 51508 BAKER F6R ASSEMBLY ASSEMBLY 1 Grab the Split Idler Gear and douse it in transmission fluid at this time then slide into the needle bearing on the bearing door MAKE SURE TO PUT THE THRUST WASHER P N TRA 916 ON THE GEAR BEFORE YOU SLIDE IT INTO PLACE Lube up the Countershaft and bushing of the Reverse Slider gear with Transmission fluid then slide the Reverse Slider Gear onto the Countershaft with the Dog Tooth pockets facing you and the fork groove to the inside Take the BAKER Reverse Shift Fork and slide it down into position on the Slider Gear fork groove while at the same time aligning the Fork Pin in the Groove Track of the Shift Drum Lube up the supplied BAKER Fork rod and slide it through the Shift Fork into the Fork Rod hole of the bearing door Refer back to Figure 2 on Page 4 Expanded View 2 Slide the Reverse Dog Clutch onto the hexed end of the Countershaft Tighten the supplied 5 18 18 Nylock Jam Nut onto the end of the Countershaft to 45 55 ft Ibs Assembly order is laid out below for reference FIGURE 18 FIGURE 19 PICTURES TAKEN ARE FROM THE BAKER R amp D BAGGER WHICH HAS CUSTOM EXHAUST AND THEREFORE HAS NO EXHAUST BRACKET ON THE FACE OF THE BEARING DOOR PAGE 14 ASSEMBLY V9 51508 19 BAKER F6R ASSEMBLY ASSEMBLY
5. SIDE COVER INSTALL MECHANICAL 1 The BAKER Mechanical Reverse Side Cover will arrive at your door step with the ball and ramp assem bly already installed with a snap ring The Solenoid Safety lever assembly will also be installed with the 1 4 diameter pull dowel You need take your stock clutch cable and screw it into the clutch port on the bottom of the side cover Use a small dab of silver anti seize to prevent the steel threads of the clutch cable from sticking to the aluminum threads of the side cover Make sure your clutch cable o ring is also in good condition at this time to reduce oil leaks in the future With all of the slack out of the clutch cable feed it through the hole in the ball ramp Using the supplied ferrule slip it over the barrel end of the cable then pull the cable back so that the cable ferrule seats in the ball ramp 2 With the supplied BAKER Reverse Side Cover gasket in place the Mechanical Clutch Actuator Rod tucked into the Mainshaft and the very important Thrust Washer on the end of the Split Idler Gear you are ready to slide the side cover onto the bearing door WHEN SLIDING THE FGR SIDE COVER ONTO THE DOOR YOU NEED TO MAKE SURE THAT THE SOLENOID PLUNGER IS PULLED OUT OF THE WAY SO THAT YOU ARE NOT TRYING TO FORCE THE SAFETY LEVER AGAINST THE END OF THE SHIFT DRUM WHICH MAY BEND IT AND OR CAUSE THE LEVER TO BIND IN THE FUTURE 3 With the Mechanical Side Cover able to rest flat against the entire gasket
6. now need to route the main wire GU Long Blade Terminal to the front of the bike from the F6R Side Cover up to the handlebars There are 3 ways to accomplish this from easy to difficult Route the wire behind the starter through the Battery Box and then under the Gas Tank Dash coming out under on the Right side of the neck Loosen the gas tank and tip it up in the back and route the wire under the Gas Tank up to the handlebars in the same position or lastly under the Gas Tank in the Factory plastic wire housing up to the Fairing No matter which method you choose care needs to be taken to ensure that the wires are not getting crimped chaffed rubbed or melted by routing them in a safe manner With the wire successfully run to the front of the bike you can plug the Female Blade Terminal into the back of the Toggle Switch Then grab the ground wire for the Toggle Switch 18 long and plug the blade Terminal into the back of the Toggle Switch Use the eyelet end to go under the 10 screw holding the large wire clamp on the right side of the neck to act as the frame ground point PAGE 20 ASSEMBLY V9 51508 19 BAKER F6R ASSEMBLY FINAL BIKE ASSEMBLY With the Transmission buttoned up the clutch cable addressed and the Reverse Toggle Switch in place you can begin to assemble the rest of the stock components back onto the bike Like the starter clutch inner amp outer primary pipes floorboards pegs saddlebags battery etc while follow
7. surface you are ready to grab the 9 supplied Y 20 SHCS and bolt the 7 cover down using the following torque sequence and Blue Thread Lock Torque to 110in lbs If you are unable to get the side cover to fully seat against the side cover gasket double check that you have fully seated the Reverse Fork Rod into the door FIGURE 20 PAGE 15 ASSEMBLY V9 51508 149 BAKER F6R ASSEMBLY ASSEMBLY SIDE COVER INSTALL HYDRAULIC 1 The BAKER Hydraulic Reverse Side Cover will arrive at your door step with the 1 500 diameter piston o rings and bleeder screw already installed The Solenoid Safety Lever assembly will also be installed with the 1 4 diameter pull dowel At this time you need to remove the Stock Clutch Lever and Stock Clutch Cable Install the Hydraulic Clutch Lever 11 16 Bore of your choice and run the line down to the Reverse Side Cover in a manner that keeps it away from hot engine components and prevents it from being kinked or bent with full movement of the front end The BAKER Reverse Side Cover is designed to accept straight 35 or 90 banjo fittings It is up to you what style will work best on your bike Bleeding of the Hydraulic Clutch is the same as a Hydraulic Brake system Clutch adjustment on the other side of the bike is the same as the stock mechanical side cover 2 With the supplied BAKER Reverse Side Cover gasket in place the Hydraulic Clutch Actuator Rod tucked into the Mainshaft and the very impo
8. transmissions or transmission kit UPS air shipment is available upon request Customer is responsible for air shipment premiums LIMITED WARRANTY BAKERm Inc F6R assemblies are guaranteed to the original purchaser to be free of manufacturing defects in materials and workmanship for a period of 2 years unlimited miles 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 BAKER u In the event warranty service is required the original purchaser must call or write BAKERtm immediately with the problem If it is deemed necessary for BAKERm 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 BAKERrw with a copy of the original invoice of purchase If after an evaluation has been made by BAKER m and a defect in materials and or workmanship is found BAKER will at BAKER s option repair or replace the defective part of the assembly Warranty card must be returned within 45 days of purchase to be valid ADDITIONAL WARRANTY 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
9. 1508 19 BAKER F6R ASSEMBLY ASSEMBLY CONTINUED FIGURE 11 FIGURE 12 3 Align the Mainshaft in the bearing door in the same manner as found on the left picture below The Mainshaft Pinion Gear is what is pressed onto the Mainshaft and it needs to pushed on with the Press similar to the picture on the right below DO NOT PUSH ON ANY PART OF THE DOOR WITH THE PRESS TO INSTALL THE Mainshaft INTO THE BEARING DOOR Take your time while pressing the mainshaft into place to make sure the gears are meshing together Using a free hand to jostle the Countershaft while pressing the Mainshaft into the door is a good way to make sure that the gears are meshing and not bound up IF YOU FEEL ANY TYPE OF BINDING OR THE COUNTERSHAFT WILL NOT FREELY SPIN STOP PRESSING AND CHECK THAT EVERYTHING IS PROPERLY LINED UP AND THE MAINSHAFT IS PERPENDICULAR TO THE BEARING DOOR AND VERTICAL TO THE RAM THE PLUNGER 4 With the pinion gear fully bottomed out on the end of the Mainshaft you are ready to move forward with the next step If you had purchased the F6F option with your BAKER Reverse Kit you can switch out the straight cut stock 5th gear Mainshaft for the BAKER Helical Cut gear at this time When installing the BAKER helical cut 5th gear take care to not overexpand the snap ring With the 2 shafts completely assembled and pressed into the bearing door bolt the bearing door into the case with the door gasket in place with the provided 5 16 18 Sock
10. 8 BAKER F6R ASSEMBLY ASSEMBLY ROAD GLIDE MODELS W FAIRING 1 While following the Factory Service Manual pull off the Outer Fairing in preparation for drilling a hole for the Reverse Toggle Switch While referencing the 2 pictures below to drill a 15 32 Hole through the inner fairing on the lower right side For aesthetics and fitment you want to have the through hole symmetrical to the Cigarette lighter on the left side of the bike After the hole has been drilled and the edges cleaned up with a small file or de burr tool slide the Toggle Switch Body through it with the serrated nut in place behind the fairing You may have to adjust this nut in or out the threads to space the Toggle Switch so that Cover can close all the way The Key Way cut into the threads of the Toggle Switch need to be facing down Slide the Toggle Switch Cover on from the other side of the fairing and thread on the Hex nut Using a small amount of Blue Thread Lock is a good idea tighten until snug DO NOT OVER TIGHTEN YOU WILL STRIP THE THREADS FIGURE 25 FIGURE 26 2 With Toggle Switch taken care of you now need to fish the main wire 72 Long Blade Ter minal to the front of the bike from the Reverse Side Cover up to the Fairing There are 3 ways to accomplish this from easy to difficult Route the wire behind the starter through the Battery Box and then under the Gas Tank Dash coming out under the Fairing on the Right side of the neck L
11. ARSET FAILURE TO DO SO COULD AND WILL RESULT IN PART DAMAGE THAT MAY INHIBIT PROPER FUNCTION OF THE TRANSMISSION AT A FURTHER DATE 4 After you checked that inside of the case is clean of debris and have wiped the bearing gasket surface clean insert the BAKER Reverse Gearset Cassette into the case while re using the Factory Bearing Door gasket After sliding the gearset into place refer back to the BAKER Reverse Bearing Door Assembly view on pg 3 for location of bolts and tighten the bolts in the order as found on the diagram below Make sure to re install the exhaust bracket at this time as well Tiahten bolts to 220 in Ibs using Blue Thread Lock 5 With the bearing door securely in place and torqued put the shifter pawl down onto the shift pins on the end of the drum through the top cover opening 6 This is a great time to check your work in assembling the F6R Gearset Cassette With the bike safely supported and the back tire off of the ground spin the back tire by hand and shift the bike forward and in reverse through all 6 gears You will have to spin the tire at a pretty decent clip to get the transmission to shift smoothly What you are mostly checking is that it easily finds each gear and that you can find neutral without any issues 7 Once you are satisfied with the function and you know that the transmission will shift you can bolt on the top cover at this time and torque it down to 110 in Ibs using Blue Thread Lock
12. SH THE SPLIT RINGS INTO POSITION AROUND THE COUNTERSHAFT TO MAKE SURE THAT THEY ARE SECURLY IN POSITION AGAINST THE SHAFT USING A SMALL AMOUNT OF AXLE GREASE ON THE SPLIT SECURING SEGMENTS WHEN INSTALLING THEM WILL HELP THEM STICK INTO PLACE WHILE YOU ARE BUILDING THE Countershaft GEAR STACK FIGURE 8 PAGE 9 ASSEMBLY V9 51508 19 BAKER F6R ASSEMBLY ASSEMBLY 1 In an attempt as to not dislodge any of the thrust washers or split securing segments do not tip over or lay the countershaft on its side until you have pressed it into the provided BAKER Reverse Bearing Door Feed the free end of the Countershaft through the bearing door and position it in a press as seen in Figures 9 and 10 We found the using the steel tube from the Inner Race Installation tool works great as a press tool for pressing the Countershaft assembly into the bearing door If you do not have one or do not have room in your press you need to use a sufficiently strong steel tube that lands on the Countershaft bearing inner race within the bearing door You must only press on the inner race of the bearing FIGURE 9 DO NOT PUSH ON ANY PART OF THE DOOR WITH THE PRESS TO INSTALL THE COUNTERSHAFT INTO THE BEARING DOOR 2 Once the Countershaft Bearing is pressed tightly against the provided BAKER Countershaft spacer you are ready to install the Mainshaft ASSEMBLY CONTINUED ON NEXT PAGE FIGURE 10 PAGE 10 ASSEMBLY V9 5
13. amp Maiden Voyage 22 Terms 23 Disclaimer PAGE 2 TABLE OF CONTENTS V9 51508 BAKER F6R INCLUDED PARTS 18 a lt N 2 I A 16 A 1 A Y L A 8 9 10 11 gt o FIGURE 1 REVERSE BEARING DOOR COMPONENTS TAG 00 JO Om ADN P N 400 RV07 31C125KCSS P 5 16 18 x 1 25 31C175KCSS P 5 16 18 x 1 75 6100 402 RV07 61807 403 RV07 RV 7040 168 6N4 6205 406 RV07 24050 RV 7050 RV 7000 6007 407 RV07 26749 Hk1412 408 RV07 10C50KCS 137RRRE LS2542 16583 00 DESCRIPTION Reverse Bearing Door SHCS SS Polished SHCS SS Polished 5 16 AN Washer Reverse Shift Drum Shift Drum Bearing Shift Drum Nut Reverse Countershaft 7 8 14 Thread Countershaft Base Nut Countershaft Bearing Retainer Plate Countershaft 1 4 20 x 5 8 BHCS Black Mainshaft Retainer Nut Mainshaft Pinion Gear Mainshaft Bearing Retainer Plate Mainshaft 1 4 x 1 2 Solid Dowel Split Idler Gear Bearing Retainer Plate Shift Drum 10 24 x 1 2 SHCS Black Pinion Gear Snap Ring Countershaft Spacer 984 x 1 654 x 118 10mm Hollow Dowel PAGE 3 INCLUDED PARTS DETAIL OTY Nanana GD RN NO a ech COE S RYN OI V9 51508 BAKER F6R INCLUDED PARTS ACTUATOR ROD REVERSE GEAR COMPONENTS TAG P N DESCRIPTION 1 413 RVO7 Reverse Side Cover Gasket 2 412 RVO7 Reverse Fork Rod 3 404 RVO7 Reverse Shift Fork 4 RV 7020 Reverse Slide Gear 5 RV 7030 Reverse Dog Clut
14. anner demonstrated in the figure below Make sure to press the 5th gear snout firmly to the right against 6th gear It is critical for the overall spacing of the gears down the countershaft If you also purchased an F6F upgrade for your bike you would press the BAKER Helical cut 5th Countershaft gear on at this point in place of the stock straight cut 5th gear FIGURE 7 2 Once you have successfully pressed the 5th Counter gear onto the shaft you are ready to reas semble the countershaft Carefully following the service manual reassemble the stock gears back onto the countershaft making sure that the gears are free of dirt and debris and that the needle bearings are well lubricated with transmission fluid before you put them onto the BAKER Reverse Countershaft The one variant in the assembly of the Countershaft gear stack is that we do not re use the spacer H D P N 5387A between 1st gear and the bearing in the door We instead use P N LS2542 as laid out in the BAKER Reverse Bearing Door assembly view on pg 3 BAKER HELICAL 5C GEAR PICTURED GREAT CARE AND ATTENTION TO DETAIL NEEDS TO BE TAKEN WHEN ASSEMBLING THE SPLIT SECURING SEGMENTS AND THE VARIOUS SPLINED THRUST WASHERS ONTO THE COUNTERSHAFT WHILE THEY ARE EASIER TO USE THAN CONVENTIONAL SNAP RINGS THEY CAN BECOME EASILY DISLODGED FROM THEIR DESIGNED POSITION AND DAMAGED WHILE PRESSING THE COUNTERSHAFT INTO THE REVERSE BEARING DOOR USE A SMALL PICK OR SCREWDRIVER TO PU
15. ch 6 62FNTEOZ 5 8 18 Nylock Jam Nut 7 TRA 916 Thrust Washer Spilt Idler Gear 8 RV7010 Split Idler Gear PAGE 4 INCLUDED PARTS DETAIL ch MM ch ch SH KH HK 0 wi FIGURE 2 V9 51508 BAKER F6R INCLUDED PARTS A REVERSE MECHANICAL SIDE COVER COMPONENTS TAG OO OO JO Om EF0N P N S 06231 66827 LP 026K 01 5316 182 1027 001 716NWSFS 91665A350 12R50PRPOP 409 RV07 25R100PDP 401 RV07 HK1412 37089 84 WT3196 987687 WT3096 3094 DSSC 68067 DESCRIPTION Reverse Safety Solenoid R16 x16 Solenoid O Ring 11 16 x 7 8 x 3 32 Safety Return Spring 3 4 Long Solenoid Plunger Spring Seat Washer Spiral Snap Ring 7 16 Shaft 1 8 x 1 2 Split Roll Pin Reverse Safety Lever 1 4 x 1 Pull Dowel Reverse Side Cover Mechanical Split Ilder Gear Bearing Clutch Rod Assy Mech 2 625 Overall Outer Ball Ramp 3 8 OD Ball Bearings Inner Ball Ramp Clutch Cable Ferrule Snap Ring Ball amp Ramp Retainer PAGE 5 INCLUDED PARTS DETAIL FIGURE 3 12 E wi ok et OC zb zb AD ok echt zc aa oct ect ect echt Set ze V9 51508 BAKER F6R INCLUDED PARTS MIBDIAISER REVERSE FIGURE 4 REVERSE HYDRUALIC SIDE COVER COMPONENTS TAG P N DESCRIPTION OTY 1 S 06231 Reverse Safety Solenoid R16x16 1 2 66827 Solenoid O Ring 11 16x7 8x3 32 1 3 LP 026K 01 S316 Safety Return Spring 3 4 Long 1 4 182 1027 001 Solenoid Plunger 1 5 716NWSFS Spring Seat Washer 1
16. ed View Diagram of the Solenoid Assembly DO NOT TIGHTEN THE REVERSE SOLENOID WITH PLIERS AS YOU WILL NOT BE ABLE TO REMOVE IT IN THE FUTURE WITH OUT DAMAGING THE SOLENOID 2 Using the Supplied Wire Clamp which is crimped around the Solenoid wires bolt it to the top cover in the right rear corner using the Stock Top Cover bolt that you left out earlier use Blue Thread Lock and tighten to 110 in Ibs FIGURE 22 PAGE 17 ASSEMBLY V9 51508 BAKER F6R ASSEMBLY ASSEMBLY FLH MODELS W FAIRING 1 While following the Factory Service Manual pull off the Outer Fairing in preparation for drilling a hole for the Reverse Toggle Switch Find the Rubber Grommet where the Throttle Cables come through the inner fairing and locate the corner as denoted on the picture below Use these locating dimensions to drill a 15 32 Hole After the hole has been drilled and the edges cleaned up with a small file or de burr tool slide the Toggle Switch Body through it with the serrated nut in place behind the fairing You may have to adjust this nut in or out the threads to space the Toggle Switch so that Cover can close all the way The Key Way cut into the threads of the Toggle Switch need to be facing down Slide the Toggle Switch Cover on from the other side of the fairing and thread on the Hex nut Using a small amount of Blue Thread Lock tighten until snug DO NOT OVER TIGHTEN YOU WILL STRIP THE THREADS y d Corner i k e a
17. et you need to loosen the nylock jam nuts on both the countershaft and mainshaft before you remove the gearset from the case A good trick is to stand with your right foot on the rear brake pedal while trying to loosen the jam nuts with a breaker bar DO NOT USE AN IMPACT GUN TO REMOVE THE SHAFT JAM NUTS AS IT HAS A GREAT TENDENCY TO DAMAGE THE THREADS OF THE MAINSHAFT THAT YOU NEED TO REUSE DISASSEMBLY CONTINUED ON NEXT PAGE PAGE 7 DISASSEMBLY V9 51508 BAKER F6R DISASSEMBLY DISASSEMBLY CONTINUED Now you can unbolt the trap door from the case and pull the gearset Lightly tap on the end of the main shaft on the primary side with a rubber mallet to loosen the entire gearset and trap door from the case You do not need to loosen the drive sprocket or remove the 6th main bottle gear to install this kit DO NOT HIT THE END OF THE MAINSHAFT WITH 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 ANY WAY 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 RACE MOVED THE SHIFTER PAWL OR SOME OTHER SOLID OBJECT IS IMPEDING THE PATH OF THE GEARSET BEFORE YOU PROCEED Once you have successfully removed t
18. et Head Cap Screws Make sure that the Countershaft Bearing Retainer Plate is not on the bearing door at this time to ensure full socket contact on the Countershaft Base Nut Tighten both the Mainshaft Retainer Nut and the Countershaft Base Nut to 45 55 ft Ibs with Red Thread Lock Using the rear brake right foot technique is necessary to achieve the full torque values When you have tightened the two shafts nuts install the Countershaft retainer plate with the provided 1 4 20 x 5 8 button head cap screws Using Red Thread Lock Torque the Retainer Plate Screws to 110 in lbs Pull the gearset back out of the transmission case in preparation for assembly of the shift system PAGE 11 ASSEMBLY V9 51508 BAKER F6R ASSEMBLY ASSEMBLY 1 With the door amp shaft assembly on the bench install the stock detent lever assembly into the BAKER Reverse Bearing Door Torque the Stock Detent Lever Bolt to 150 in Ibs using Blue Thread Lock Stock Detent Lever Spring Pocket Stock Detent Lever Pivot Hole BAIGER pm 4004R707 5 FIGURE 13 2 Pull the Detent Lever out of the way of the drum see Service Manual and slide the drum through from the inside of the bearing door through the bearing that is already pressed into the door lt is a tight slip fit so it may take a little wiggling to get the drum to seat against the drum bearing inner race When the Shift Drum is all the way in you can let go of the detent ever Fo
19. he gearset from the case and have it sitting with the trap door on a workbench with 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 the mainshaft and all of its gears Following the service manual disassemble the countershaft down to 5th gear You will then need to use a Split Bearing Press Tool to press the stock 5th gear off of the countershaft You then similar to the picture need to press the gear off of the shaft You must ensure that you have everything lined up completely vertical and parallel to the ram on the press Getting the gear cocked or crooked on the shaft can and will result in both gear and countershaft damage ANY TIME THAT YOU ARE USING A HYDRAULIC PRESS OF ANY SIZE CARE NEEDS TO BE TAKEN TO MAKE SURE THAT YOU ARE OPERATING THE PRESS IN A SAFE MANNER AND THAT THE MACHINE IS IN GOOD WORKING ORDER USING ADEQUATE AND SOLID PIECES OF MATERIAL TO PUSH ON THE COUNTERSHAFT WILL PREVENT IT FROM SLIPPING OUT OF THE STACK WHILE UNDER LOAD ITIS COMPLETELY IN YOUR BEST INTEREST AND PERSONAL SAFETY TO BE CAREFUL IN YOUR HYDRAULIC PRESS OPERATION PAGE 8 ASSEMBLY V9 51508 BAKER F6R ASSEMBLY ASSEMBLY 1 Once you have removed the stock 5th gear from the Countershaft you are ready to press that gear onto the BAKER Reverse Countershaft Flip the shaft and tool over and press the gear onto the shaft in the m
20. ing the Factory Service Manual The Main Wire that runs up to the Toggle Switch gets plugged into the Weatherpak connector coming off of the Reverse Solenoid while the power lead off of the Solenoid is bolted into place on the post of the starter with the power ignition wires Make sure that the 2 wires coming off of the Solenoid are neatly tucked away from the exhaust and are zip tied to the neutral and sensor wires that run in the same area When you have successfully reassembled your motorcycle take the time to double check that you have replaced all of the parts and that none are left on the lift garage floor work bench etc Double check to make sure that you put Primary and Transmission Fluid in the bike Take the time to double check the drain plugs are tight and to wipe down the bearing door side cover and primary to make sure there are no leaks after the maiden voyage REVERSE SYSTEM OPERATION BAKER Reverse Shift Pattern R 1 N 2 3 4 5 6 In order to shift the motorcycle into Reverse you need to be at a complete stop in First Gear You pull the clutch in hold the Reverse Safety Toggle Switch and then using the Foot Shifter push it DOWN into Reverse Once it has shifted into Reverse you can and need to let go of the Reverse Safety Toggle Switch Holding the switch on for extended periods of time will burn out the solenoid Then you let out the clutch and apply the throttle similar to slowly maneuvering your bike a tight parking l
21. lebags if applicable then the floorboards pegs and the pipes Remember to disconnect the O2 sensor plugs from the pipes so as to not damage them when pulling the pipes off Unbolt the starter pull it out and set aside on your workbench Pull off the outer primary the primary chain clutch assembly and the inner primary Having a drip pan underneath the bike when you are taking off the outer primary is a great idea as residual oil will get all over your lift or garage floor depending on your work environment Pull the bearing race found on the mainshaft next with your Inner Race Service tool You can not pull the gearset out of the case without first removing this bearing race Loosen the bolts on the transmission side cover pull it off detach from the clutch cable and set it aside The side cover along with the factory ball and ramp will not re used with the BAKER F6R kit REMOVE THE TRANSMISSION DIPSTICK AT THIS TIME AS WELL YOU CAN NOT PULL THE GEARSET WITH THE DIPSTICK IN THE TRANSMISSION IT WILL BREAK OFF IF YOU LEAVE IT IN THE TRANSMISSION WHEN ATTEMPTING TO PULL THE GEARSET Remove the top cover and set aside this is necessary so that you can pull the shifter pawl off of the drum when you remove the entire gearset and trap door assembly According to the Factory Service Manual you want to place the shifter pawl on the top cover mounting surface with the gasket acting as a pad while pulling the gearset Using a 1 1 16 6 pt sock
22. llowing Figure 14 and using the provided BAKER Shift Drum socket grab on the other end of the drum with an adjustable wrench and tighten the drum nut onto the Shift Drum The shift drum nut is directional install with the round snout pointing inward to land on the inner race of the shift drum bearing Tighten the drum nut to 25 ft lbs using Red Thread Lock ASSEMBLY CONTINUED ON NEXT PAGE FIGURE 14 PAGE 12 ASSEMBLY V9 51508 Xa BAKER F6R ASSEMBLY ASSEMBLY CONTINUED 3 The stock shift forks and fork rods will be re used While referencing the Factory Service Manual slide the shift forks into their corresponding fork grooves on the stock dog clutches With the forks in their correct positions and the pins residing within the correct shift track on the drum slide the fork rods into place through the shift forks and into the fork rod bores within the back of the BAKER Reverse Door Lubing the fork rods with transmission fluid before installation is a good measure of proactive wear resistance Once the fork rods are in their correct positions tap on the ends of them with a ball peen hammer until they Dead Head into the bottom of the fork rod bores You have now successfully assembled the Reverse Gearset Cassette to the point that you can bolt it in the case for good WHEN SEATING THE FORK RODS INTO THE DOOR WITH A HAMMER GREAT CARE NEEDS TO BE TAKEN NOT HIT ANY OF THE GEARS FORKS DRUM OR ANY OTHER PARTS OF THE GE
23. oosen the gas tank and tip it up in the back and fish the wire under the Gas Tank up to the Fairing in the same position or as we did on our BAKER R amp D Bagger under the gas tank in the Factory plastic wire housing up to the Fairing No matter which method you choose cares needs to be taken to ensure that the wires are not getting crimped chaffed rubbed or melted by running them in a safe manner With the wire successfully run to the front of the bike you can plug the Female Blade Terminal into the back of the Toggle Switch Grab the ground wire for the Toggle Switch 30 long plug the blade Terminal into the back of the Toggle Switch use the eyelet end to go under the 10 screw holding the large wire clamp on the right side of the neck to act as the frame ground point Use a couple of zip ties to secure the wires within the inside of the Fairing as well as the main wire when it passes by the neck Re Install the Outer Fairing following the Factory Service Manual PAGE 19 ASSEMBLY V9 51508 BAKER F6R ASSEMBLY ASSEMBLY HANDLEBAR MOUNTED F6R SAFETY SWITCH NON FAIRING MODELS 1 Using the provided 10 24 x1 2 SS SHCS s bolt the handlebar mount to the bars in such a way that it won t hit the tank at any position in the travel of the bars and is easily accesible to you when in a riding position v 4 H d D a Ca EN FIGURE 28 EXAMPLES OF A 2008 DYNA FIGURE 29 2 With the Toggle Switch taken care of you
24. ot When done backing the bike up with the bike stopped grab the clutch and using the foot shifter shift UP into 1st gear You do not need to hit the Reverse Safety Switch to shift the bike back into 1st gear Once back into 1st gear make sure by pushing down on the Shift Lever that you can not go back into Reverse that let s you as the rider know that the Safety Lever is doing it s job by blocking you from shifting into Reverse without hitting the Reverse Safety Toggle Switch Once securely back into 1st gear you are free to ride around with the stock 1 6 shift pattern WHEREAS IT MAY BE TEMPTING TO TRY AND RIDE FAST IN REVERSE IT IS NOT AS EASY AS YOU THINK THE FRONT END RAKE OF YOUR BIKE MAKES IT VERY EASY TO TIP OVER SHOULD YOU START HORSING AROUND WITH YOUR BUDDIES When you take off for your test ride ease into it and slowly accelerate through the gears to ensure that you reassembled the vehicle in a functional and safe manner additionally you can make sure all of the components are functioning in their designed manners PAGE 21 ASSEMBLY V9 51508 SPECIAL ORDERS A minimum 500 deposit is reguired with all special orders Special orders include unigue case finishes unigue side door reguests 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
25. 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 BAKERm 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 primaries belt drives and Wide Tire Kits are designed exclusively for use in Harley Davidsone motorcycles BAKERrtm shall have no warranty or liability obligation if a BAKER part is used in any other application If it is determined that a BAKERrm transmission assembly has been disassembled during the warranty period for any PAGE 22 TERMS V9 51508 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
26. 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 FOR QUESTIONS ORDERS OB SUPPORT TOLL FREE 1 877 640 2004 WWW BAKERDRIVETRAIN COM BAISER STV ETRA PREMIUM DRIVETRAIN INNOVATIONS FOR AMERICAN MOTORCYCLES PHONE 517 339 3835 FAX 517 339 4590 9804 E SAGINAW HASLETT MI 48840 PAGE 23 DISCLAIMER V9 51508
27. rive Transmissions can handle the job While regularly referring to the Factory Service Manual for your bike A must for this kit as well our multiple diagrams and in depth instructions there should not be any issues with the conversion process While the BAKER F6R was designed to be as easy an install as possible this is probably not the job for a weekend warrior as there is no substitute for experience TOOLS amp PARTS HYDRUALIC SIDE COVER VERSION Common hand tools sockets allen wrenches and DOT 5 Silicone Brake Fluid Spectro P N I GABF snap ring pliers will suffice for a majority of the job 11 16 Bore Hydraulic Clutch Lever while a few specialty tools that are required are 3AN Brake line listed out below BAKER does sell some of our 3 8 24 Banjo Bolt own drivetrain related tools as well the P N s are 10mm Brake Line Fittings listed out below 1 3 16 6 pt Socket Clutch Sprocket Nut 1 1 16 6 pt Socket Tranny Shaft Nylock Nuts 1 3 8 6 pt Socket Countershaft Base Nut Primary Inner Race Service Kit BAKER TOOLB 56 Split Bearing Puller BAKER P N 483 6T Customers installing a BAKER F6R on Screaming Eagle bikes with Factory installed Hydraulic side covers will need to purchase the following parts from their local Harley Davidson dealer 45 oz of Primary Fluid Spectro Heavy Duty Primary P N 37090 98A Center Push Rod Qty 1 Chain Case Oil Spectro P N R GAPCL P N 37092 06 Screw Adjuster Qt
28. rtant Thrust Washer on the end of the Split Idler Gear you are ready to slide the side cover onto the bearing door WHEN SLIDING THE F6R SIDE COVER ONTO THE DOOR YOU NEED TO MAKE SURE THAT THE SOLENOID PLUNGER IS PULLED OUT SO THAT YOU ARE NOT TRYING TO FORCE THE SAFETY LEVER AGAINST THE END OF THE SHIFT DRUM WHICH MAY BEND IT AND OR CAUSE THE LEVER TO BIND DOWN THE ROAD 3 With the Hydraulic Side Cover able to rest flat against the entire gasket surface you are ready to grab the 9 supplied 14 20 SHCS 7 and bolt the cover down using the following torque sequence and Blue Thread Lock Torque to 110in Ibs If you are unable to get the side cover to fully seat against the side cover gasket double check that you have fully seated the Reverse Fork Rod into the door 8 FIGURE 21 PAGE 16 ASSEMBLY V9 51508 BAKER F6R ASSEMBLY ASSEMBLY SOLENOID INSTALL 1 Contained in the hardware for this kit is the Reverse Safety Spring This part is integral in keeping the Safety Lever in place on the Shift Drum during times of forward movement on the bike Slide the Reverse Spring Seat Washer P N 716NWSFS over the Reverse Plunger then the Spring P N LP 026K 01 316 Apply a small amount of Silver Anti Seize to the threads of the provided Reverse Solenoid and thread it into the side cover 3 4 24 Threads Sufficiently tighten the solenoid by hand ensuring the O ring is fully seated into the side cover See pg 6 for the Explod
29. y 1 Blue Thread Lock P N 37903 90 Release Plate Qty 1 Red Thread Lock P N 37909 90 Retaining Ring Internal Qty 1 Access To A 20 Ton Hydraulic Press P N 7848W Jam Nut Qty 1 Silver Anti Seize Black Zip Ties 32 Oz Of Transmission Fluid BAKER recommends Spectro Oils PAGE 1 GETTING STARTED TOOLS These parts retro fit the clutch rod and adjustment to a mechanical ball and ramp side cover set up to work with the BAKER 1 5 piston and push rod in the F6R Sidecover V9 51508 BAKER F6R TABLE OF CONTENTS TABLE OF CONTENTS Cover Reverse System Overview amp Tools Table of Contents Reverse Bearing Door Components Exploded View Of Reverse Gears Reverse Side Cover Contents Mechanical Reverse Side Cover Contents Hydraulic Disassembly Of Bike Pull Stock Gearset Cassette Disassembly Stock Gearset Cassette Reverse Countershaft Assembly a ewe Se Se eS LY Se 0 Pressing Mainshaft Into Reverse Bearing Door 11 Pressing Countershaft into Reverse Bearing Door 12 13 Shift System amp F6R Gearset Cassette 14 Installation Of Reverse Gears 15 Reverse Side Install Mechanical 16 Reverse Side Install Hydraulic 17 Reverse Solenoid Install 18 Reverse Safety Switch amp Harness FLH Fairing Models 19 Reverse Safety Switch amp Harness Road Glide Models 20 Reverse Satety Switch amp Harness Non Fairing Models Dyna Softail Road King 21 Final Bike Assembly Reverse Operation
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