F5R - Baker Drivetrain
Contents
1. gt lt V6 4 12 11 FACTORY 5 SPEED REVERSE DISASSEMBLY SIMILAR TO ANY OTHER DRIVETRAIN RELATED PROJECT THE FIRST STEP THAT YOU WANT TO TAKE IS TO REMOVE THE SEAT AND DISCONNECT THE BATTERY FOR YOUR OWN SAFETY NOW IS ALSO A GOOD TIME TO DRAIN THE PRIMARY AND TRANSMISSION FLUID FOR LOCATIONS OF APPLICABLE DRAIN PLUGS CHECK YOUR SERVICE MANUAL 1 While referencing your Factory Service Manual section 7 follow the gearset removal procedure If you are installing the F5R Retro Fit Kit on your stock 5 speed you do not need to remove your main drive gear but do need to remove the secondary drive pulley sprocket in order to install the provided fork rod pn 122 6R FF during the F5R gearset install 2 With the gearset out of the motorcycle begin stripping the gears off of the shaft down to the bearing door Care must be taken to ensure that no gear teeth are damaged during the disassembly process as you are re using all of your gears except the stock countershaft When removing the factory split cage needle bearings only open them enough to slide up the shaft rather than pulling them off to the side This will help prevent cracks to the plastic cage of the bearings Press the mainshaft out of the bearing door 3 Clean the transmission case out with brake cleaner or another suitable cleaner at this time and inspect it for issues that may affect the installation of the gearset or cause leaks down the road Includi2. thread lock to install the four 5 16 18 x 1 25 door bolts 31C125KCSS P with washers 6100 and three 20 x 1 25 door bolts PN 25C125KCSS P amp PN 23207 with washers PN 6099SS at this time Torque the 5 16 bolts to 220 in lbs and the 1 4 bolts to 130 in Ibs in the order shown in figure 5 i 3 T a M E m e Hi T A jw I lz R gt CO J i m 7 FIGURE 6 6 Slide the gears in the transmission to lock it in two gears and remove the countershaft retainer plate PN 406 F5R to ensure full socket contact with the retainer nut on the countershaft While using red thread lock torque the countershaft 168 F5R snout of nut facing door bearing and mainshaft PN RV 7050 nuts to 45 50 ft lbs DO NOT USE AN IMPACT GUN TO TIGHTEN EITHER SHAFT RETAINING NUT AS YOU RISK DAMAGE TO THE NUTS AND OR SHAFTS BY DOING SO PAGE 10 F5R GEARSET ASSEMBLY 7 Install the countershaft retainer plate using red thread lock and torque each 7 20 x 625 button head pn 24050 to 130 in Ibs Install the shift system at this point while referencing your Factory Service Manual Install the provided fork rod PN122 6R FF from the primary side of the motorcycle and run the transmission through all the gears multiples time before proceeding with the FOR reverse gear train installation to ensure the gearset was correctly assembled With correct transmission f
3. 1 25 SHCS SS Ya AN Washer SS Bearing Door FSR Ya 20 X 1 25 SHCS Black Oxide Thrust Washer Countershaft Countershaft FoR Gasket Bearing Door PAGE 7 LEGEND F5R HYDRAULIC SIDE COVER RETRO FIT KIT V6 4 12 11 FACTORY 5 SPEED REVERSE F5R BUILDER S KIT GEARSET EXPLODED VIEW FIGURE 3 DESCRIPTION 1 2 5RN A 1 Shift Drum Assembly 2 23207 4 14 20 X 1 25 SHCS Black Oxide 3 33001 4 Washer 10 Plain 4 103 5E 1 Shift Fork gt Gear Mainshaft 5 122 6R FF 1 Shift Fork Rod F5R 6 500 Overall 6 102 5F 1 Shift Fork 3 Gear Countershaft 7 101 56E 1 Shift Fork oe Gear Mainshaft 8 11067A 5 Snap Ring External Gearset 9 61005 1 5 Gear Countershaft 10 62212M 2 2 Gear C S 3 Gear M S 11 8876 4 Split Cage Needle Bearing 12 6003B 5 Thrust Washer Gearset 13 603M2C 2 3 Gear M S 2 Gear C S 14 52491C 1 2 94 1 Gear Countershaft 14 51324C 1 3 24 1 Gear Countershaft 15 51234C 1 4 Gear Countershaft 16 12035B 1 Oil Seal Main Drive Gear 17 HK2520 2 Caged Needle Bearing 5 M S 18 33344 94 1 Pulley Spacer 19 12067B 1 Seal Roller Bearing 5 M S 20 1302 334PP 1 Snap Ring Internal Beveled 3 11 32 21 11165A 1 Quad Seal 22 6209 1 Roller Bearing 5 M S 23 61005M 1 Main Drive Gear 5 M S 24 51294M 1 2 94 1 Gear Mainshaft 24 51324M 1 3 24 1 Gear Mainshaft 25 61234M 1 4 Gear Mainshaft PAGE 8 EXPLODED VIEW F5R BUIDLER S KIT
4. PN LP 026K 01 S316 fired the lockout plunger PN 182 F5R in the way of the reverse fork mechanically preventing you from accidentally shifting into reverse BEFORE YOU START PUTTING THE REST OF THE MOTORCYCLE BACK TOGETHER DISCONNECT THE BATTERY THIS IS SOLELY FOR YOUR SAFETY WHILE WORKING ON THE MOTORCYCLE PAGE 18 REVERSE FUNCTION TEST V6 4 12 11 Fal 7 Ba gt ES 7 Jk w K e Et Si pn ATO 20 Standard 20A Automotive Style Blade Fuse Existing 12V Ignition Wire To Keyed Ignition Switch pn 428 F5R Switches 12V Wire Assembly 100 Overall Exisiting 12V Ignition Wire To Main Fuse Block FH ATO WR Inline Blade Fuse Holder pn SCB 646 Step Down Heat Shrink Butt Connector pn 7200018 Momentary Toggle Switch gt Reverse Lockout Solenoid pn ATO 20 Standard 20 Automotive Style Blade Fuse Existing 12V Ignition Wire To Keyed Ignition Switch pn 428 F5R Switches 12V Wire Assembly 100 Overall Exisiting 12V Ignition Wire To Main Fuse Block pn FH ATO WR Inline Blade Fuse Holder pn SCB 646 Step Down Heat Shrink Butt Connector pn 7200018 Momentary Toggle Switch o Reverse Lockout Solenoid 73185 Toggle Shifting Solenoid pn 420S F5R Shifting Solenoid Assembly Existing Neutral Switch Light Wire pn 424 F5R Solenoid To Switches Wire Assembly 90 Ov
5. battery box from the transmission the back bone under the gas tank and by the neck to the toggle switches Take care to make sure the wires are securely in place to prevent chaffing binding or pinching refer to figure 17 3 the 6 stud ring terminals with Apcs of the provided PN A 850 female blade terminals make sure to slide on the provided Shrink tube to each wire before crimping the terminals 4 Torque the four 10 24 x 1 2 SHCS SS PN 10C50KCSS screws to 85 in lbs in a X pattern using blue thread lock to ensure the housing and switches stay in place on the handlebars PAGE 17 WIRING HANDLE BAR MOUNTED WIRING HARNESS V6 4 12 11 FACTORY 5 SPEED REVERSE REVERSE FUNCTION TEST 1 With all of the wires hooked up and double checked against Figure 17 you are ready to do a reverse functionality test Temporarily hook up the battery With the bike ignition on and the bike in neutral the first check is that the Safety Switch the momentary style switch activates the Safety solenoid You will hear an audible click of the solenoid This lets you know that you have the wires hooked up correctly If you do not hear an audible click then you need to double check that the safety smaller diameter lower solenoid is hooked up to the momentary switch 2 With the bike in neutral and the back tire off of the lift or shop floor spin the back tire by hand to enable the shifting dogs on t
6. housing that you ordered Take care to make sure the wires are securely in place to prevent chaffing binding or pinching PAGE 15 FSR WIRING 12V POWER SOURCE V6 4 12 11 BAKER FACTORY 5 SPEED REVERSE H D BRAKE LEVER PERCH MOUNTED SWITCH HOUSING 1 If you choose either switch housing assembly Satin Black SHB A or Chrome SHC A installation is the same Both units have the Toggle Switches 7200018 Momentan Screw Terminals amp PN 73185 ON OFF Screw Terminals installed in them and the rubber boots are snug Remove the factory handle bar inner clamp reusing the factory torx head bolts amp washers with blue thread lock torque to 120 in Ibs Set the factory clamp aside 2 Locate the solenoid toggle switch wires PN 424 F5R and run them up through the battery box from the transmission up the back bone under the gas tank and by the neck to the toggle switches Take care to make sure the wires are securely in place to prevent chaffing binding or pinching Before sliding all 4 wires into the switch housing PN 422 F5RB slide the provided protective sleeve over the wires refer to figure 17 3 Arrange the wires as shown in Figure 12 The wires are a tight fit and no different than dealing with the factory switch housing for the RUN OFF amp START buttons care needs to be taken to prevent shorting out the wires by crimping them in the housing or chaffing on each other After installing them on the toggle s
7. onto the shafts can commence at this time while reference the factory service manual for your model of motorcycle 2 Provided are seven gearset snap rings PN 11067A Six are needed and one is extra as they are easy to overstretch Pre lube all of the split cage needle bearings with new transmission fluid before installing them TAKE CARE TO ONLY OPEN UP THE GEARSET SNAP RINGS ENOUGH TO SLIDE THEM DOWN THE SPLINES INTO THEIR PROPER POSITION ON THE SHAFTS PAGE 9 DISASSEMBLY F5R GEARSET ASSEMBLY gt lt V6 4 12 11 BAKER FACTORY 5 SPEED REVERSE FIGURE 5 3 Hang the provided door gasket PN 35652 79B on the transmission case door pins 4 With the gearset assembled wrap the clutch nut threads and splines on the mainshaft with electrical tape before sliding the gearset into the case to protect the new oil seal PN 12035B in the main drive gear 5 Depending on the brand of exhaust that you have on your motorcycle and the subsequent mounting brackets now is a good time to do a dry fit of the exhaust bracket and side cover 401 F5R Mechanical or PN 429 F5R Hydrualic with side cover gasket PN 414 F5R to determine if any modifications need to be made to your exhaust bracket Also install the crush washers banjo fitting and hydraulic clutch line at this time on hydraulic side cover models to assess the clearance for those parts as well When satisfied with the exhaust bracket mounting proceed with blue
8. safely into reverse every time e need to use the starter motor for reverse maneuvers e Includes ready to install solenoids and neutral safety switch wiring e Reverse can only be selected when bike is in neutral by tying the solenoid function to the neutral switch on the transmission e modifications required for reverse gearset installation REQUIRED READING Regardless of the skill level or experience of the technician installing the FSR Retro Fit Kit or FoR Builder s kit it is highly recommended that a genuine H D Parts Catalog and Factory Service Manual be available for your model of motorcycle TOOLS amp PARTS e Common Hand Tools e Wire Cutters Strippers e Silver Anti Seize e Heat Gun e Access ToA 20 Ton Hydraulic Press e Voltmeter e Primary Drive Service Kit Gaskets e Torque Wrench 3 8 8 1 2 Drive e 13 16 6 pt Socket Clutch Nut e Calipers or 6 Machinists Scale e 1 1 2 6 pt Socket Motor Sprocket Nut HYDRAULIC VERSION PARTS e Primary Inner Race Service Kit 11 16 Bore Master Cylinder Clutch BAKER PN TOOLB 56 eee my e 3202 Primary Fluid 3 8 24 Thread Banjo Bolt Spectro PN R GAPCL e DOT 5 Silicone Based Brake Fluid e 22 2402 Transmssion Fluid e 10mm Banjo Fitting Angle Depends On Spectro PN BD75140 Exhaust Bracket Style e Blue amp Red Thread Lock F5R BUILDER KIT OR COMPLETE BUILD TRANSMISSIONS Portions of these installation instructions do no a
9. ACTORY 5 SPEED REVERSE TAG 137RRRE RV 7000 RV 7051 37089 84L 124 56L 66827 45 9404 25C150KCSS P 25C225KCSS P 429 F5R 51740 001 414 F5R 519705 008 01 31F31KKCS 25R75PDP HK1412 TRA 916 RV 7010 408 F5R RV 7030 RV 7020 168 F5R 420 F5R 420S F5R LW 05611 0325 404 5 412 RV07 407 5 24050 31C125KCSS P 6100 26749 25C125KCSS P 6099SS 1 5ERV 23207 LS2542 412 F5R 35652 79B OTY AQ NNN A BR CE AO N N M 1 DESCRIPTION Snap Ring External 01 375 Shaft Driven Pinion Gear Retainer Nut Mainshaft Actuator Rod Assembly 2 810 Overall Piston LSD O Ring Buna Hydraulic Piston Bleeder Valve Ya 20 x 1 50 SHCS SS Ya 20 x 2 25 SHCS SS Side Cover Hydrualic Drain amp Oil Level Plug 3 8 24 Gasket Side Cover Fill Plug Zero Leak 16 5 16 24 x 5 16 Set Screw SS Ya x Pull Dowel Needle Bearing Split Idler Gear Thrust Washer Split Idler Gear Split Idler Gear Jam Nut Countershaft Dog Clutch Slider Gear Retainer Nut Countershaft Solenoid Assembly Lockout solenoid Assembly Shifting Redux Return Spring Shift Fork Reverse Fork Rod Reverse Bearing Retainer Plate Mainshaft Ya 20 x 625 BHCS Black Oxide Bearing Retainer Plate Countershaft Roller Bearing Mainshaft Roller Bearing Countershaft 5 16 18 x 1 25 SHCS SS 5 16 AN Washer SS Ya 2 Alignment Dowel Ya 20 X
10. ING OR IT WILL BREAK OFF IN THE SIDE COVER 2 Insert the plunger PN 185 F5R with bell crank installed on it in the solenoid port from the inside of the side cover without the washer or spring Refer to Figure 10 for orientation of the bell crank when installed Slide the washer and spring over the plunger from the solenoid port side 3 Apply anti seize to the threads on the solenoids and thread them in by hand with the side cover off of the motorcycle Install the lockout solenoid PN 420 F5R as a complete assembly as shown in Figure 9 DO NOT TIGHTEN THE SOLENOIDS WITH ANYTHING OTHER THAN YOUR HANDS RUN THE SOLENOIDS ALL THE WAY IN UNTIL THEY BOTTOM OUT IN THE SIDE COVER TAKE CARE WHEN THREADING THE SOLENOIDS IN TO NOT GET THE WIRES TWISTED AT THE POINT THEY COME OUT THE BACK OF THE SOLENOID ANYTIME THE SOLENOIDS NEED TO BE REMOVED IN THE FUTURE FOR REGULAR MOTORCYCLE SERVICE MAKE SURE THEY ARE UNPLUGGED SO YOU ARE NOT PINCHING THE WIRES CAUSING A POSSIBLE FAILURE POINT PAGE 12 F5R MECHANICAL SIDE COVER COMPONENTS V6 4 12 11 BAKER FACTORY 5 SPEED REVERSE 4 With the solenoids installed slide the pull 25R75PDP part of the way into the side cover to hold bell crank out of the way while installing the side cover on the bearing door Make sure to have the threaded end 8 32 thread of the dowel facing up when you install it 5 Grab two of the side cover bolts and thread them into the door to hold the side c
11. PN 584 F5R and gasket PN 415 F5R back on the side cover and install the top bolt 25C62KCSS and one of the bottom bolts PN 73753 to hold the ball and ramp assembly in place during installation of the FOR solenoid wiring harness and reverse function testing Skip to page 15 for wiring harness installation FIGURE 10 PAGE 13 F5R MECHANICAL SIDE COVER COMPONENTS V6 4 12 11 BAKER FACTORY 5 SPEED REVERSE FSR HYDRAULIC SIDE COVER COMPONENTS INSTALLATION 1 Insert the plunger PN 185 F5R with bell crank installed on it in the solenoid port from the inside of the side cover without the washer or spring Refer to Figure 10 for orientation of the bell crank when installed Slide the washer and spring over the plunger from the solenoid port side 2 Apply anti seize to the threads on the solenoids and thread them in by hand with the side cover off of the motorcycle Install the lockout solenoid PN 420 F5R as a complete assembly as shown in Figure 9 DO NOT TIGHTEN THE SOLENOIDS WITH ANYTHING OTHER THAN YOUR HANDS RUN THE SOLENOIDS ALL THE WAY IN UNTIL THEY BOTTOM OUT IN THE SIDE COVER TAKE CARE WHEN THREADING THE SOLENOIDS IN TO NOT GET THE WIRES TWISTED AT THE POINT THEY COME OUT THE BACK OF THE SOLENOID ANYTIME THE SOLENOIDS NEED TO BE REMOVED IN THE FUTURE FOR REGULAR MOTORCYCLE SERVICE MAKE SURE THEY ARE UNPLUGGED SO YOU ARE NOT PINCHING THE WIRES CAUSING A POSSIBLE FAILURE POINT 3 With the solenoids installed s
12. T ENOUGH TO FEEL REVERSE ENGAGE ONCE ENGAGED PULL THE CLUTCH LEVER BACK IN e LET GO OF BOTH TOGGLE SWITCHES e SLOWLY LET OUT THE CLUTCH LEVER AND WHILE USING CAUTION BACK UP IN REVERSE e WHEN YOU ARE DONE BACKING UP COME A COMPLETE STOP WITH THE CLUTCH LEVER PULLED IN TURN THE REVERSE SHIFTING SWITCH OFF DOWN YOU ARE NOW IN NEUTRAL AND LOCKED OUT OF REVERSE e PULL THE CLUTCH LEVER IN AND SHIFT INTO FIRST GEAR TAKE OFF AND HIT THE OPEN ROAD Safety Switch Reverse Shifting Switch Momentary ON OFF FIGURE 19 PAGE 21 REVERSE USAGE INSTRUCTIONS V6 4 12 11 BAKER FACTORY 5 SPEED REVERSE TERMS SPECIAL ORDERS 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 BAKERT Inc F5R Retro Fit Kit is 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 BAKER Inc F5R transmission assemblies and transmission builder s kits are guaranteed t
13. V6 4 12 11 FACTORY 5 SPEED REVERSE INSTALLATION INSTRUCTIONS FITMENT amp OPTIONS PN F5 RV 1 1990 1997 All Factory 5 Speed Models PN F5 RV 2 1998 1999 Softail 1998 2000 FLT FLH amp Dyna 1999 FXR PN F5 RV 3 2000 2006 Softail 2001 2006 FLT FLH 2001 2005 Dyna Add P Suffix For Polished Door And Side Cover Add C Suffix For Chrome Door And Side Cover Add U Suffix For Upgrade To BAKER 005 Builder s Kit Or Complete Build Add H Suffix For Hydraulic Side Cover Version PN SHB A H D Hand Control Mounted Switch Housing Satin Black Powdercoat PN SHC A H D Hand Control Mounted Switch Housing Chrome PN 423 F5R 1 Handlebar Mounted Switch Housing Assembly Polished 2000 2006 Softail Models Require BAKER PN TCSO A Oil Line Adapter Kit PAGE 1 OVERVIEW V6 4 12 11 FACTORY 5 SPEED REVERSE TABLE OF CONTENTS 1 Cover 2 Table Of Contents 3 Overview Features Getting Started Tools Required 4 Exploded View FoR Mechanical Side Cover Kit 5 Exploded View Legend F5R Mechanical Side Cover Kit 6 Exploded View FoR Hydraulic Side Cover Kit 7 Exploded View Legend F5R Hydraulic Side Cover Kit 8 Exploded View amp Legend F5R Builder s Kit 9 Disassembly F5R Gearset Assembly 10 F5R Gearset Assembly 11 F5R Gearset Assembly 12 F5R Mechanical Side Cover Components 13 F5R Mechanical Side Cover Components 14 F5R Hydraulic Side Cover Components 15 Wiring Harne
14. andling 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 any other application If it is determined that BAKER transmission assembly has been disassembled during the warranty period for any reason this limited warranty will no longer apply PAGE 22 TERMS V6 4 12 11 FACTORY 5 SPEED REVERSE 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 dutie
15. erall 426 F5R Solenoids To Neutral Switch Wire Assembly pn 420 F5R Reverse Lockout a Solenoid Assembly F5R 1 pn A 321 10 Eyelet For 10 Screw pn 427 F5R Neutral Switch To Ground Wire Assembly 4 Overall pn 21 458 Neutral Switch 2 Pole Screw Terminals Normally Open pn 73185 On Off Toggle Shifting Solenoid pn 420S F5R Shifting Solenoid Assembly Existing Neutral Switch Light Wire pn 424 F5R Solenoid To Switches Wire Assembly 90 Overall pn 426 F5R Solenoids To Neutral Switch Wire Assembly pn A 321 10 Eyelet For 10 Screw Existing Neutral Switch Ground Wire F5 RV 2 L t Solenoid Assembly pn 21 438 Neutral Switch 2 Pole Screw Terminals Normally Closed F5 RV 3 pn 21 458 Neutrdl Switch 2 Pole Screw Terminals Normally Open FIGURE 17 PAGE 19 WIRING DIAGRAM V6 4 12 11 BAKER FACTORY 5 SPEED REVERSE FINISH LINE 1 With reverse installation validated by passing the reverse function test you ready to install the side cover and ball and ramp cover for good mechanical side cover version For the hydraulic versions you can now fully tighten the banjo fitting and hydraulic line fittings Using blue thread lock install all of the side cover bolts and torque to them to 130 in lbs using the numerical torque sequence in Figure 18 Following the alpha torque sequence in Figure 18 and using blue thread lock torque the ball and ramp co
16. ft FIGURE 8 13 Install the top cover with the provided neutral switch PN varies depending on the kit you ordered per your Factory Service Manual at this time Torque the neutral switch to 135 in Ibs Double check that the transmission is in neutral and that you have proper neutral switch function by using a voltmeter to check for continuity PAGE 11 F5R GEARSET ASSEMBLY V6 4 12 11 BAKER FACTORY 5 SPEED REVERSE FSR MECHANICAL SIDE COVER COMPONENTS INSTALLATION PN 420S F5R Shifting Solenoid Assembly TAG PN OTY DESCRIPTION 1 S 22 150 1 R22x22 12V Pull Solenoid 1 410 F5R 1 Shifting Solenoid Cover 2 OR568119 1 O ring 1 00 ID 3 1 0323 01 316 1 Return Spring 720 ID 4 PB26165 1 Spring Seat 625 ID 5 WSM 62 1 Spiral Snap Ring 625 6 26735 1 3 16 X 1 2 Solid Dowel T 185 F5R 1 Shifting Plunger 8 409 F5R 1 Shifting Bell Crank PN 420 F5R Reverse Lock Out Solenoid Assembly TAG PN QTY DESCRIPTION 9 S 062311 1 R16x16 12V Pull Solenoid 10 66827 1 O ring 750 ID 11 LP 026K 01 S316 1 Return Spring 475 ID 12 716NWSFS 1 Spring Seat 440 ID 13 91665A350 1 Spiral Snap Ring 440 ID 14 182 F5R 1 Lockout Plunger FIGURE 9 1 Apply anti seize to the threads and install the mechanical clutch cable into the side cover Check to make sure the clutch cable o ring is in good working condition if it is not replace it at this time DO NOT OVER TIGHTEN THE CLUTCH CABLE FITT
17. he reverse gears to get aligned In one motion activate the safety switch hold it ON and then hit the shifting switch The transmission should be in reverse at this time Perform this test a few times until you are satisfied that the reverse shifting function works properly More complete reverse usage instructions can be found on page 21 SAFETY SWITCH OFF SAFETY SWITCH ON wi Es my BA a U FIGURE 15 mem FIGURE 16 In the OFF position the plunger of the In the ON position the plunger of the Safety solenoid mechanically blocks Safety solenoid clears the shift fork and allows the bike from being shifted into reverse the bike to be shifted into reverse The motorcycle will remain in reverse as long as the shifting solenoid is powered and the bike is neutral If you turn off the shifting switch the F5R will automatically shift back to neutral by nature of the redundant return spring design on the shifting solenoid and shift fork If you shift the bike out of neutral it will kill the power to the solenoid and automatically shift out of reverse the moment power is cut If the bike was running and you were to shift the foot lever out of neutral while the shifting switch is ON and you did not first turn it off there is no chance that the bike would try to shift into reverse the next time that you go into neutral by nature of the reverse safety solenoid design When the power was cut to the solenoids the return spring
18. lide the dowel PN 25R75PDP part of the way into the side cover to hold bell crank out of the way while installing the side cover on the bearing door Make sure to have the threaded end 8 32 thread of the dowel facing you when you install it 4 Grab two of the side cover bolts and thread them into the door to hold the side cover in place during installation of the crank PN 409 F5R on to the reverse shift fork PN 404 F5R 5 Remove the pull dowel and with a pick or a small screwdriver slide the bell crank slot over the fork pin Final installation should like Figure 10 Reinstall the pull dowel A little wiggling of the bell crank may be necessary to line up the pivot hole with the pull dowel Install the set screw 31F31KKCS with blue thread lock and screw in until it is flush with the top of the side cover 6 Install two crush washers and banjo fitting 3 8 24 thread at this time Hold off fully tightening the banjo bolt and line fittings until the side cover is fully installed with all the bolts in place PAGE 14 FSR HYDRAULIC SIDE COVER COMPONENTS V6 4 12 11 FACTORY 5 SPEED REVERSE FSR WIRING HARNESS INSTALLATION Based on the year and model of your motorcycle there are 3 different configurations of the same basic wiring harness used as laid out in Figure 17 The following steps will lay out in detail how to install the wires and switches IGNITION WIRE 12V POWER SOURCE 1 While
19. lug Zero Leak 34 16 19 31F31KKCS 1 5 16 24 x 5 16 Set Screw SS 20 25R75PDP 1 Ya Pull Dowel 21 HK1412 2 Needle Bearing Split Idler Gear 22 TRA 916 2 Thrust Washer Split Idler Gear 23 RV 7010 1 Split Idler Gear 24 408 F5R 1 Jam Nut Countershaft 25 RV 7030 1 Dog Clutch 26 RV 7020 1 Slider Gear 27 168 F5R 1 Retainer Nut Countershaft 28 420 F5R 1 Solenoid Assembly Lockout 29 420S F5R 1 Solenoid Assembly Shifting 30 LW 05611 0325 1 Redux Return Spring 31 404 F5R 1 Shift Fork Reverse 32 412 RV07 1 Fork Rod Reverse 33 407 F5R 1 Bearing Retainer Plate Mainshaft 34 24050 6 Ya 20 x 625 BHCS Black Oxide 35 406 F5R 1 Bearing Retainer Plate Countershaft 36 6007 1 Roller Bearing Mainshaft 37 6205 1 Roller Bearing Countershaft 38 31C125KCSS P 4 5 16 18 x 1 25 SHCS SS 39 6100 4 5 16 Washer SS 40 26749 2 Ya x 2 Alignment Dowel 41 25C125KCSS P 2 Ya 20 X 1 25 SHCS SS 42 6099SS 2 Ya AN Washer SS 43 1 5ERV 1 Bearing Door FOR 44 23207 1 Ya 20 X 1 25 SHCS Black Oxide 45 LS2542 2 Thrust Washer Countershaft 46 412 F5R 1 Countershaft FoR 47 35652 79B 1 Gasket Bearing Door PAGE 5 LEGEND F5R MECHANICAL SIDE COVER RETRO FIT KIT V6 4 12 11 bo 7 Ba E 5 7 Jk ES K K PA FSR HYDRAULIC SIDE COVER RETRO FIT KIT EXPLODED VIEW FIGURE 2 PAGE 6 EXPLODED VIEW HYDRAULIC SIDE COVER RETRO FIT KIT V6 4 12 11 BAKER F
20. ng but not limited to bad threads in the case gouges in the gaskets surfaces residual build up of thread lock and that the case bearings spin freely and smoothly Also take this time to inspect the split cage needle bearings for any cracks heat spots or evidence of being run low on oil or without oil IF THERE IS ANY DOUBT ABOUT THE VIABILITY TO RE USE ANY OF THE SPLIT CAGE NEEDLE BEARINGS AFTER THEY ARE INSPECTED REPLACE THEM 4 Install the provided Main Drive Gear Oil Seal 12035B roller bearing seal PN 12067B and quad seal PN 11165 at this time With the old seal of out the main drive check to make the outboard most needle bearing has not walked towards the transmission If so reference your Factory Service Manual in order to replace it with a new bearing GEARSET ASSEMBLY RETRO FIT 1 Press the stock mainshaft into the provided BAKER F5R bearing door pn 1 5ERV making sure to fully support the inner race of the bearing to maintain it s integrity Re use the stock mainshaft spacer H D PN 35064 79 with stepped side of the spacer facing away from the bearing door Now press in the provided BAKER F5R countershaft PN 412 F5R while using the two provided thrust washers LS2542 Make sure to fully support and only press on the inner race of the door bearing PN 6205 to install the countershaft With both shafts fully bottomed out on their applicable thrust washers Re assembly of the stock gears
21. o the original purchaser to be free of manufacturing defects in materials and workmanship for a period of 5 years from the date of purchase or up to 50 000 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 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 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 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 relevant improper installation accident modification including but not limited to use of unauthorized parts racing high performance application mish
22. over in place during installation of the bell crank PN 409 F5R on to the reverse shift fork PN 404 F5R 6 Remove the and with a pick or a small screwdriver slide the crank slot over the fork pin Final installation should like Figure 10 Reinstall the pull dowel A little wiggling of the bell may be necessary to line up the pivot hole with the pull dowel Install the set screw PN 31F31KKCS with blue thread lock and screw in until it is flush with the top of the side cover 7 Remove the ball and ramp cover PN 584 F5R and gasket 415 F5R 8 Lay the inner ball ramp PN 3096 F5R on a workbench and fill each of the three pockets with enough axle grease to hold the ball bearings PN 987687 in place during assembly Place the ball bearings in the greased pockets and then the outer ball ramp 3196 F5R on top While making sure to hold the ramps together slide them into the side cover Align the tab on the outer ramp with the corresponding pocket in the side cover The cable attachment boss of the inner ramp should be pointing towards the rear of the motorcycle when installed 9 With all of the adjustment out of the clutch cable full slack slide the clutch cable through the inner ball ramp enough that you can then slide the ferrule PN 3094 DSSC over the end of the cable Carefully pull on the clutch lever enough to get the ferrule seated in the ball ramp pocket 10 Place the ball and ramp cover
23. pply to you if you bought a F5R Builder s kit or a complete transmission with F5R upgrade but the wiring installation notes reverse function tests and the general F5R riding usage instructions do If you have a builders kit reference your Factory Service for the instructions on how to swap out the main drive gear main drive gear roller bearing and main drive gear roller bearing seal As well as the installation of your secondary drive belt pulley or chain sprocket for torque specs PAGE 3 GETTING STARTED V6 4 12 11 FACTORY 5 SPEED REVERSE FSR MECHANICAL SIDE COVER RETRO FIT KIT EXPLODED VIEW FIGURE 1 PAGE 4 EXPLODED VIEW F5R MECHANICAL SIDE COVER RETRO FIT KIT V6 4 12 11 BAKER FACTORY 5 SPEED REVERSE TAG PN OTY DESCRIPTION 1 137RRRE 1 Snap Ring External 01 375 Shaft 2 RV 7000 1 Driven Pinion Gear 3 RV 7051 1 Retainer Nut Mainshaft 4 37089 84 1 Actuator Rod Assembly 2 625 Overall 5 3096 F5R 1 Ball Ramp Inner 6 987687 3 Ball Bearing 03 8 7 3094 DSSC 1 Ferrule Clutch Cable 8 3196 F5R 1 Ball Ramp Outer 9 415 F5R 1 Gasket Ball amp Ramp Cover 10 584 F5R 1 Ball amp Ramp Cover 11 25C62KCSS 3 Ya 20 x 625 SHCS SS 12 73753 2 Ya 20 x 625 SS 13 25C150KCSS P 7 Ya 20 x 1 50 SHCS SS 14 25C225KCSS P 1 Ya 20 x 2 25 SHCS SS 15 401 F5R 1 Side Cover Mechanical 16 51740 001 2 Drain amp Oil Level Plug 3 8 24 17 414 F5R 1 Gasket Side Cover 18 51970S 008 01 1 Fill P
24. referencing your Factory Service Manual trace down the main ignition wire on your motorcycle as shown in Figure 11 Cut the wire a few inches before it splits off to enter the main fuse block and strip the insulation back 1 4 on each wire You are going to splice in the power wire for the reverse shifting and safety toggles switches here Take care to install the provided inline fuse holder in such a manner that it easily accessible should you ever need to change the standard size 20A blade fuse 2 The provided step down heat shrink butt connector PN SCB 646 needs to be crimped in the same manner as a standard butt connector but also has the added feature of containing heat activated glue to further adhere the wires together and provide a weather tight seal Twist the keyed ignition side wire together with the bare wire end of the provided toggle switch to 12V power wire assembly PN 428 F5R and slide into the plain end of the PN SCB 646 splice butt connector Crimp the connector to the two wires making sure that you have them securely in place Insert the fuse block side ignition wire into the striped end of the connector and crimp it in place Using a heat gun shrink the connector to the wires PROVIDED WIRE PN 428 F5R e KA Ll MAIN FUSE BLOCK SIDE OF CONNECTION FIGURE 11 3 Run the wires up to the handlebars via the back bone under the gas tank and by the right side of the neck in preparation for installing the switch
25. s and risks associated therewith CUSTOMER SUPPORT For any installation or service questions please contact our BAKER technical department toll free 1 877 640 2004 BAKER DRIVETRAIN 9804 E SAGINAW HASLETT MI 48840 On the web www bakerdrivetrain com DRIVETRAIN PREMIUM DRIVETRAIN INNOVATIONS FOR AMERICAN MOTORCYCLES PAGE 23 DISCLAIMER
26. ss 12V Ignition Wire Source 16 Wiring Harness Factory Hand Control Mounted Switch Housing 17 Wiring Harness 1 Handlebar Mounted Switch Housing 18 Reverse Function Test 19 Wiring Diagrams 20 Finish Line 21 F5R Usage Instructions 22 Terms 23 Disclaimer PAGE 2 TABLE OF CONTENTS V6 4 12 11 FACTORY 5 SPEED REVERSE OVERVIEW We introduced the F6R kit or Factory 6 speed Reverse for the 2007 later H D 6 speed bike The biggest advantage of the F6R is the ability to engage reverse from one switch in the handle bar area without the need to reach down near the hot exhaust Minimal clutch modulation is required in reverse to launch the vehicle due to the short gear ratio We finally got off our duff and are doing the same for the 1990 2006 5 speed bikes We call it the F5R or Factory 5 speed Reverse The contents the FOR kit are similar to the F6R door side cover countershaft reverse gear train and hardware Existing gearset except countershaft shift system and top cover will be re used with the FSR installation The FSR will be appreciated by those with heavy GVW applications trikes side cars and trailers or those with compromised leg mobility FEATURES e Reverse selection controlled by aircraft grade shifting solenoid amp bell crank assembly Electronic reverse safety lock out solenoid must first be energized with the provided handle bar or inner fairing mounted momentary toggle switch Shift
27. unction validated install the secondary drive pulley sprocket and belt chain at this time while referencing your Factory Service Manual 10 Install the reverse side cover components while referencing the exploded views on pg 4 and legend on pg 5 Remember to place a thrust washer PN TRA 916 behind the split V6 4 12 11 FACTORY 5 SPEED REVERSE FIGURE 7 INSTALLATION PICTURES TAKEN USING THE BAKER 1999 ROAD KING WHICH HAS CUSTOM EXHAUST AND THEREFORE HAS NO EXHAUST BRACKET ON THE FACE OF THE BEARING DOOR idler gear PN RV 7010 Install slider gear RV 7020 and dog clutch PN RV 7030 Torque the countershaft Jam Nut PN 408 F5R to 33 35 ft lbs using red thread lock 11 Slide the shift fork PN 404 F5R onto the slider gear and rotate up into place to slide the provided fork rod PN 412 RV07 into the bore in the bearing door Fully seat the fork rod with your hand but do not hit it with a hammer you do not need to do so and will struggle to remove it in the future by binding it in the bearing door Place the redux return spring PN LW 05611 0325 on the fork rod Place the other provided thrust washer PN TRA 916 on the outboard pinion of the split idler gear Hang the side cover gasket PN 415 F5R the door at this time as well 12 Re use and install your center clutch rod and slide the provided clutch push rod assembly 37089 84 Mechanical or 37089 84L Hydraulic into the mainsha
28. ver bolts to 130 in lbs as well 5 3 2 o 5 4 Kei E Ar S d gek Ku za CH 4 A i Y a A EMILE Tee pa z R s e i i Ka 34 E d LEFEL 1 Bi we I IC AC D n 3 a D Kail 8 j o 1 4 ern b WE ee E 5 i 3 FIGURE 18 2 Fill transmission with 22 24 oz of transmission via the 3 4 16 fill plug PN 519705 008 01 hole on top of the side cover Put a small amount of anti seize on the fill plugs threads and install turn until snug Do not over tighten or you risk damaging the o ring 3 The BAKER Hydraulic side cover pistons are designed for use ONLY with DOT 5 Silicone Based Brake Fluid Fill the clutch reservoir with clean fluid and bleed the air out of the system in the same manner as Hydraulic Motorcycle Brake systems 4 Finish installing the primary drive and adjust the clutch cable while referencing your Factory Service Manual Exhaust controls outer fairing and then the battery can be hooked up for good You are ready for a full test ride PAGE 20 FINISH LINE V6 4 12 11 FACTORY 5 SPEED REVERSE PLEASE REMOVE THIS PAGE FROM THE INSTRUCTIONS AND KEEP WITH YOUR MOTORCYCLE FOR REFERENCE HOW TO OPERATE YOUR BAKER F5R e WITH YOUR MOTORCYCLE IN NEUTRAL PULL IN THE CLUTCH LEVER AND HOLD IT e ACTIVATE AND HOLD BOTH TOGGLE SWITCHES IN THE ON UP POSITION e SLOWLY LET THE CLUTCH LEVER OUT JUS
29. witches wrap the terminals and wires with electrical tape Gently slide the 4 wires back through the housing and install the two provided 10 24x Y2 Stainless Bolts 10C50KCSS Torque to 85 in lbs with blue thread lock 4 While referencing your Factory Service Manual locate the neutral switch wires and cut off the factory end s at the neutral switch on the transmission top cover Slide on the provided 1 8 dia heat shrink and eyelet s PN A 321 10 crimp the eyelets in place and slide the heat shrink over the Shrink the tubing with a heat gun 5 Install the neutral switch to solenoid ground wire PN 426 F5R as shown in Figure 17 Also install the other neutral switch terminal wire at this time as shown in Figure 17 Model year dependent PAGE 16 F5R WIRING FACTORY HAND CONTROL MOUNTED SWITCH HOUSING V6 4 12 11 FACTORY 5 SPEED REVERSE HANDLEBAR MOUNTED SWITCH HOUSING 1 If you ordered a separate handlebar mounted switch housing assembly PN 423 F5R it comes with the toggle switches already installed and nn to go All you have to do is find a spot on your 1 diameter handlebars that will allow the housing to fully camp to the bars This spot will need to clear the gas tank with the bars at full lock in either direction and ensure the wires will not get pinched or experience chaffing from the bars turning 2 Locate the solenoid toggle switch wires PN 424 F5R and run them up through the
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