BAKER DD6 REVERSE - Baker Drivetrain
Contents
1. PAGE 18 DD6 RV WIRING FACTORY HAND CONTROL MOUNTED SWITCH HOUSING V4 4 13 11 BAKER DD6 REVERSE HANDLEBAR MOUNTED SWITCH HOUSING 1 If you ordered a handlebar mounted switch housing assembly PN 423 F5R it comes with the toggle switches already installed and ready to go All W have to do is find a spot on your 1 diameter handlebars that will allow the housing to fully clamp to the bars This spot will need to clear the gas tank with the bars at full lock in either direction and that the wires will not get pinched or experience chaffing from the bars turning 2 Install the wires the same as the Bat Wing Fairing models 3 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 on place on the handlebars PAGE 19 DD6 RV WIRING HANDLE BAR MOUNTED WIRING HARNESS V4 4 13 11 BAKER DD6 REVERSE REVERSE FUNCTION TEST 1 With all of the wires hooked up and double checked against Figure 15 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 sma2. 6 14 20 x 625 BHCS Black Oxide 30 406 F5R 1 Bearing Retainer Plate Countershaft 31 6007 1 Roller Bearing Mainshaft 32 6205 1 Roller Bearing Countershaft 33 31C125KCSS P 4 5 16 18 x 1 25 SHCS SS 34 6100 4 5 16 AN Washer SS 35 26 49 2 Ya x 2 Alignment Dowel 36 25C125KCSS P 2 Ya 20 X 1 25 SHCS SS 37 6099SS 2 Ya AN Washer SS 38 132 DD6RV 1 Bearing Door DD6 RV 39 23207 1 Ya 20 X 1 25 SHCS Black Oxide 40 LS2542 1 Thrust Washer Countershaft 45 413 DD6RV 1 Countershaft DD6 RV 46 35652 79B 1 Gasket Bearing Door PAGE 7 EXPLODED VIEW LEGEND DD6 RV MECHANICAL SIDE COVER KIT V4 4 13 11 BAKER DD6 REVERSE DD6 RV BUILDER S KIT GEARSET EXPLODED VIEW FIGURE 3 PAGE 8 EXPLODED VIEW DD6 RV BUILDER S KIT V4 4 13 11 BAKER DD6 REVERSE PN 555 56 555 56L A 12045 694 HW 68010 70813 152 56A DD6 2C 1 8876A 6003B 11067A DD6 3C 1 DD6 1C 1 DD6 1C 2 94 DD6 4C DD6 5C 124E DD6A 23207 33001 174 DD6 173 DD6 172 DD6 122 6R FF DD6 MS DD6 MS 2 94 34091 85X 12035B HK2520 33344 945 12067B 1302 334PP 11165A 6209 DD6 6M 1 DD6 2M 1 DD6 3M 1 DD6 4M 1 DD6 4C5 1 DD6 5M 1 TWD1423 OTY A A A A A A A A A A A sch N A A A sch NA A O OTO DESCRIPTION Shifter Pawl Assembly EVO Models Shifter Pawl Assembly Twin Cam Models Seal Shifter Pawl Washer Shifter Pawl Snap Ring External 7 Jam Nut Eccentric Screw 7 16 14 Eccentric Shif
3. jam nut PN 408 F5R to 33 35 ft lbs using red thread lock 18 Slide the shift fork PN 404 F5R onto the slider gear and rotate it up into place to slide the provided fork rod PN 412 RVOT7 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 03255 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 on the door at this time as well 19 Re use and install your center clutch rod and slide the provided clutch push rod assembly PN 37089 84 Mechanical or PN 37089 84L Hydraulic into the mainshaft FIGURE 7 FIGURE 8 20 Install the top cover with the provided neutral switch PN 21 438 per your Factory Service Manual at this time Torque the neutral switch to 135 in lbs Double check that the transmission is in neutral and that you have proper neutral switch function by using a voltmeter to check for continuitv PAGE 13 DD6 RV GEARSET ASSEMBLY V4 4 13 11 BAKER DD6 REVERSE DD6 RV 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 LP 0323 01 531
4. 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 Plug Zero Leak 34 16 19 31F31KKCS 1 5 16 24 x 5 16 Set Screw SS 20 25R75PDP 1 Ya x 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 03258 1 Redux Return Spring 31 404 F5R 1 Shift Fork Reverse 32 412 RVO7 1 Fork Rod Reverse 33 407 F5R 1 Bearing Retainer Plate Mainshaft 34 24050 6 14 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 AN Washer SS 40 26749 2 Ya x 2 Alignment Dowel 41 25C125KCSS P 2 Ya 20 X 1 25 SHCS SS 42 609955 2 Ya AN Washer SS 43 132 DDERV 1 Bearing Door DD6 RV 44 23207 1 14 20 X 1 25 SHCS Black Oxide 45 LS2542 1 Thrust Washer Countershaft 46 413 DD6RV 1 Countershaft DD6 RV 47 35652 79B 1 Gasket Bearing Door PAGE 5 EXPLODED VIEW LEGEND DD6 RV MECHANICAL SIDE COVER KIT V4 4 13 11 BAKER DD6 REVERSE DDG RV HYDRAULIC SIDE COVER RETRO FIT KIT EXPLODED VIEW F
5. 6 1 Return Spring 20 ID 4 PB26165 1 Spring Seat 625 ID 5 WSM 62 1 Spiral Snap Ring 625 6 26 35 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 FITTING 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 WHE
6. AN MOTORCYCLES PAGE 25 DISCLAIMER
7. Control Mounted Switch Housing 19 Wiring Harness 1 Handlebar Mounted Switch Housing 20 Reverse Function Test 21 Wiring Diagram 22 Finish Line 23 DD6 RV Usage Instructions 24 Terms 25 Disclaimer PAGE 2 TABLE OF CONTENTS V4 4 13 11 BAKER DD6 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 DD6 RV or Direct Drive 6 Speed Reverse The contents in the DD6 RV 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 DD6 RV installation The DD6 RV 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 safely into reverse every time e need to use the start
8. F31KKCS with blue thread lock and screw in until it is flush with the top of the side cover 6 Install two crush washers banjo fitting 3 8 24 thread and hydraulic line at this time Hold off fully tightening the banjo bolt and line fittings until the side cover is fully installed PAGE 16 DD6 RV HYDRAULIC SIDE COVER COMPONENTS V4 4 13 11 BAKER DD6 REVERSE DDG RV WIRING HARNESS INSTALLATION Based on the year and model of your motorcvcle there are 2 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 various wires and switches IGNITION WIRE 12V POWER SOURCE 1 While referencing your Factory Service Manual trace down the main ignition wire on your motorcvcle 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 s
9. HIFTING 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 QN OFF FIGURE 19 PAGE 23 REVERSE USAGE INSTRUCTIONS V4 4 13 11 BAKER DD6 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 BAKER Inc DD6 RV 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 TV Inc DD6 RV transmission assemblies and DD6 RV transmission builders kits are guaranteed to 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 repair
10. IGURE 2 PAGE 6 EXPLODED VIEW DD6 RV HYDRAULIC SIDE COVER RETRO FIT V4 4 13 11 BAKER DD6 REVERSE TAG PN QTV DESCRIPTION 1 137RRRE 1 Snap Ring External 1 375 Shaft 2 RV 7000 1 Driven Pinion Gear 3 RV 7051 1 Retainer Nut Mainshaft 4 37089 84L 1 Actuator Rod Assembly 2 810 overall 5 124 56L 1 Piston 01 500 LSD 5 124 56L10 1 Piston 91 000 2007 newer Indian D 66827 2 O Ring Buna 1 5 OD Hydraulic Piston D 9452K29 1 O Ring 1 OD 3 4 ID Hydraulic Piston D 9452K81 1 O Ring 1 OD 13 16 ID Hydraulic Piston 45 9404 1 Bleeder Valve 8 25C150KCSS P 7 Ya 20 x 1 50 SHCS SS 9 25C225KCSS P 1 Ya 20 x 2 25 SHCS SS 10 429 F5R 1 Side Cover 1 5 Hydraulic Bore 10 429 F5R I 1 Side Cover 01 0 Hydraulic Bore 11 51740 001 2 Drain amp Oil Level Plug 3 8 24 12 414 F5R 1 Gasket Side Cover 13 51970S 008 01 1 Fill Plug Zero Leak 16 14 31F31KKCS 1 5 16 24 x 5 16 Set Screw SS 15 25R75PDP 1 Ya Ya Pull Dowel 16 HK1412 2 Needle Bearing Split Idler Gear 17 TRA 916 2 Thrust Washer Split Idler Gear 18 RV 7010 1 Split Idler Gear 19 408 F5R 1 Jam Nut Countershaft 20 RV 7030 1 Dog Clutch 21 RV 7020 1 Slider Gear 22 168 F5R 1 Retainer Nut Countershaft 23 420 F5R 1 Solenoid Assembly Lockout 24 420S F5R 1 solenoid Assembly Shifting 25 LW 05611 0325S 1 Redux Return Spring 26 404 F5R 1 Shift Fork Reverse 27 412 RVO7 1 Fork Rod Reverse 28 407 F5R 1 Bearing Retainer Plate Mainshaft 29 24050
11. L e 22 2407 Transmssion Fluid Spectro PN BD75140 DD6 RV BUILDER S KIT OR COMPLETE BUILD TRANSMISSIONS Portions of these installation instructions do not apply to you if you bought a DD6 RV Builder s kit or a complete transmission with DD6 RV upgrade but the wiring installation notes reverse function tests and the general DD6 RV riding usage instructions do If you have a builders kit reference your Factory Service Manual 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 OVERVIEW GETTING STARTED V4 4 13 11 BAKER DD6 REVERSE DDG RV MECHANICAL SIDE COVER RETRO FIT KIT EXPLODED VIEW FIGURE 1 PAGE 4 EXPLODED VIEW DD6 RV MECHANICAL SIDE COVER RETRO FIT KIT V4 4 13 11 BAKER DD6 REVERSE TAG PN QTV DESCRIPTION 1 137RRRE 1 Snap Ring External 1 375 Shaft 2 RV 7000 1 Driven Pinion Gear 3 RV 7051 1 Retainer Nut Mainshaft 4 3 089 84 1 Actuator Rod Assembiv 2 625 Overall 5 3096 F5R 1 Ball 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 14 20 x 625 SS 13 25C150KCSS P 7 Ya 20 x 1 50 SHCS SS 14 25C225KCSS P 1 14 20
12. LY DD6 RV RETRO FIT KIT 1 Preheat an oven to 450 and place 4th PN DD6 4C 1 and 5th PN DD6 5C 1 gears in the oven for 25 30 minutes in preparation for pressing them on the provided DDG RV countershaft PN 413 DD6RV DO NOT HEAT THE GEARS WITH A TORCH ANY OTHER FORM OF DIRECT HEAT OR ANY NON THERMOSTATICALLV CONTROLLED OVEN AS YOU WILL DAMAGE THE HEAT TREAT ON THE SURFACE OF THE GEARS DO NOT PRESS ON THE GEARS AT ROOM TEMPERATURE THE GEARS ARE DESIGNED WITH A LARGE AMOUNT OF PRESS TO HOLD THEM IN PLACE UNDER LOAD PRESSING THEM ON COLD WILL INDUCE STRESS RISERS IN THE GEAR AND OR THE COUNTERSHAFT THIS WILL CAUSE PREMATURE WEAR RELATED ISSUES THAT WILL NOT BE COVERED UNDER WARRANTY DUE TO IMPROPER INSTALLATION PROCEDURE 2 Provided are six gearset snap rings PN 11067A Five 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 3 Assemble the countershaft gear cluster while referencing the gearset exploded view and legend on pages 6 and 7 With 1st 2nd and 3rd gear on the shaft the snap rings securely in place and 4 and 5 gear properly heated Press the gears on the shaft in the proper orientation See Figure 2 and make sure to fully seat them on the shaft for proper gear alignment in the transm
13. N 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 14 DD6 RV MECHANICAL SIDE COVER COMPONENTS V4 4 13 11 BAKER DD6 REVERSE 4 With the solenoids installed slide the pull dowel PN 25R75PDP part of the way into the side cover to hold bell crank out of the wav 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 cover in place during installation of the bell crank PN 409 F5R on to the reverse shift fork PN 404 F5R 6 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 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 PN 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
14. O gt lt PAGE 12 DD6 RV GEARSET ASSEMBLY V4 4 13 11 BAKER DD6 REVERSE 12 Install the countershaft retainer plate using red thread lock and torque each 74 20 x 625 button head pn 24050 to 130 in lbs 13 Install the shift system at this point while referencing the exploded view on page 6 Install the provided fork rod PN122 6R FF from the primarv side of the motorcvcle 14 Torque the four pillow block bolts PN 23207 to 130 in Ibs using blue thread lock Adjust the shifter pawl over the drum pins to 010 with the transmission in 3 gear and torque the eccentric adjuster jam nut PN 70813 to 20 ft lbs with blue thread lock INSTALLATION PICTURES TAKEN USING THE 15 Run the transmission through all the gears BAKER 1999 ROAD KING WHICH HAS multiples time before proceeding with the CUSTOM EXHAUST AND THEREFORE HAS NO DD6 RV reverse geartrain installation to KYHAUST BRACKET ON THE FACE OF THE ensure the gearset was correctly BEARING DOOR assembled 16 With correct transmission function validated install the secondary drive pulley sprocket and belt chain at this time while referencing your Factory Service Manual 17 Install the reverse side cover components while referencing the exploded views on page 4 and legend on page 5 Remember to place a thrust washer PN TRA 916 behind the split idler gear PN RV 7010 Install sllider gear PN RV 7020 and dog clutch PN RV 7030 Torque the countershaft
15. PN 987687 in place during assembly Place the ball bearings in the greased pockets and then the outer ball ramp PN 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 PN 584 F5R and gasket PN 415 F5R back on the side cover and install the top bolt PN 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 15 DD6 RV MECHANICAL SIDE COVER COMPONENTS V4 4 13 11 BAKER DD6 REVERSE DD6 RV 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 pl
16. V4 4 13 11 BAKER DD6 REVERSE FITMENT amp OPTIONS PN DD6 RV Retro fits all BAKER DD6 Gearsets Add P Suffix For Polished Door And Side Cover Add C Suffix For Chrome Door And Side Cover Add U Suffix For Upgrade To A BAKER DD6 Builder s Kit Or Complete Transmission Add H Suffix For Hydraulic Side Cover Version Add HI Suffix For Hydrualic Side Cover 2007 Newer Indian 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 5 1 Handlebar Mounted Switch Housing Assembly Polished 2000 2006 Softail Models Require BAKER PN TCSO A Oil Line Adapter Kit PAGE 1 FITMENT V4 4 13 11 BAKER DD6 REVERSE TABLE OF CONTENTS 1 Cover 2 Table Of Contents 3 Overview Features Getting Started Tools Required 4 Exploded View DD6 RV Mechanical Side Cover Kit 5 Exploded View Legend DD6 RV Mechanical Side Cover Kit 6 Exploded View DD6 RV Hydraulic Side Cover Kit 7 Exploded View Legend DD6 RV Hydraulic Side Cover Kit 8 Exploded View DD6 RV Gearset 9 Exploded View Legend DD6 RV Gearset 10 Disassembly 11 Disassembly DD6 RV Gearset Assembly 12 DD6 RV Gearset Assembly 13 DD6 RV Gearset Assembly 14 DD6 RV Mechanical Side Cover Components 15 DD6 RV Mechanical Side Cover Components 16 DD6 RV Hydraulic Side Cover Components 17 Wiring Harness 12V Ignition Wire Source 18 Wiring Harness Factory Hand
17. e the ball and ramp cover bolts to 130 in lbs as well 7 a S il Kg A CH d 5 A re i d 1 d 1 ma Fi 1 Dau TEE 7 5 rt ke Ca ah LEVEL H A AP x fay 0 D Ta Ben i SP H SI d Kies ZE 4 Te D 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 vou risk wrecking the o ring 3 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 22 FINISH LINE V4 4 13 11 BAKER DD6 REVERSE PLEASE REMOVE THIS PAGE FROM THE INSTRUCTIONS AND KEEP WITH YOUR MOTORCYCLE FOR REFERENCE HOW TO OPERATE YOUR BAKER DD6 REVERSE 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 SLOWLX LET THE CLUTCH LEVER OUT JUST 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 TO A COMPLETE STOP WITH THE CLUTCH LEVER PULLED IN TURN THE REVERSE S
18. eal 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 LA MAINFUSE 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 housing that you ordered Take care to make sure the wires are securely in place to prevent chaffing binding or pinching PAGE 17 DD6 RV WIRING 12V POWER SOURCE V4 4 13 11 BAKER DD6 REVERSE H D BRAKE LEVER PERCH MOUNTED SWITCH HOUSING 1 If vou choose either switch housing assembiv Satin Black PN SHB A or Chrome PN SHC A installation is the same Both units have the Toggle Switches PN 7200018 Momentarv Screw Terminals amp PN 73185 ON OFF Screw Terminals installed in them and the rubber boots are snug Remove the factorv handle bar inner clamp reusing the factorv torx head bolts amp washers with blue thread lock torque to 120 in lbs Set the factory clamp aside Locate the solenoid toggle switch wires PN 424 F5R and run them up
19. ed 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 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 C
20. er 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 No case modifications required for reverse gearset installation REQUIRED READING Regardless of the skill level or experience of the technician installing the DD6 RV Retro Fit Kit or DD6 RV Builders 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 Blue amp Red Thread Lock e Wire Cutters Strippers e Silver Anti Seize e Dielectric Grease e Access To A 20 Ton Hydraulic Press e Heat Gun e Primary Drive Service Kit Gaskets e Voltmeter Seals Lock Tabs etc e Split Bearing Press Tool HYDRAULIC VERSION PARTS BAKER PN 483 DD6RV e 11 16 Bore Master Cylinder Clutch e Torque Wrench 3 8 amp 1 2 Drive Lever Assembly 1 3 16 6 pt Socket Clutch Nut e 3 8 24 Thread Banjo Bolt E e DOT 5 Silicone Based Brake Fluid e 6 Calipers or 6 Machinists Scale 2007 8 Newer Indian Models With e Access To An Oven Stock Controls Require Prestone DOT e Primary Inner Race Service Kit 4 Synthetic Brake Fluid BAKER PN TOOLB 56 e 10mm Banjo Fitting Angle Depends On e 3202 Primary Fluid Exhaust Bracket Style Spectro PN R GAPC
21. ff 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 lockout solenoid When the power was cut to the solenoids the return spring PN LP 026K 01 8316 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 tai BACK TOGETHER DISCONNECT THE BATTERY THIS IS SOLELY FOR YOUR SAFETY WHILE WORKING ON THE MOTORCYCLE PAGE 20 REVERSE FUNCTION TEST V4 4 13 11 fal 7 p gt o a A k pn ATO 20 20 Automotive Style Blode Fuse Existing 12V Ignition Wire To Keyed Ignition Switch pn 428 F5R Switches To 12V Wire Assembly 100 Overoll Exisiting 12V Ignition Wire To Moin Fuse Block pn FH ATO WR Inline Blode Fuse Holder pn SCB 646 Step Down Heot Shrink Butt Connector pn 7200018 Momentary Toggle Switch e Reverse Lockout Solenoid pn 20 Standord 20 Automotive Style Blade Fuse Existing 12V Ignition Wire To Keyed Ignition Switch pn 428 F5R Switches To Wire Assembly 100 Overall 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 Momentory Toggle Switch Be Reverse Lockout Solenoid pn 73185 On Off Toggle Shifting Solenoid p
22. g the gearset into the case to protect the new oil seal PN 12035B in the main drive gear 10 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 PN 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 thread lock to install the four 5 16 18 x 1 25 door bolts PN 31C125KCSS P with washers PN 6100 and three 74 20 x 1 25 door bolts PN 25C125KCSS P 8 PN 23207 with washers PN 609955 at this time Torque the 5 16 bolts to 220 in Ibs and the 1 4 bolts to 130 in lbs in the order shown in figure 5 7 FIGURE 6 11 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 PN 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 S
23. ission 4 Slide the provided countershaft thrust washer PN LS 2542 onto the countershaft in preparation for pressing the shafts into the bearing door 5 With 3rd gear PN DD6 3M 1 on the mainshaft but not held in place with a snap ring slide the mainshaft into the bearing door Make sure that you re use the hardened mainshaft thrust washer PN TWD 1423 on the end of the mainshaft While you press the mainshaft into the door bearing PN 6007 make sure to fully support the inner race of the bearing to maintain its integrity Fully seat the mainshaft in the door against the thrust washer 6 Press the countershaft gear cluster into the bearing door making sure to fully support the inner race of the bearing PN 6205 to maintain its integrity Support 3rd gear PN DD6 3M 1 with your hand to make sure it is meshing with 3rd gear PN DD6 3C 1 on the countershaft 7 With both shafts pressed into the bearing door and fully bottomed out on their applicable thrust washers install the thrust washer PN 6003B and snap ring PN 11067A on the mainshaft to hold 3rd gear PN DD6 3M 1 in place Slide 2nd gear PN DD6 2M 1 onto the mainshaft at this time PAGE 11 DISASSEMBLY DD6 RV GEARSET ASSEMBLY V4 4 13 11 BAKER DD6 REVERSE 8 Hang the provided door gasket PN 35652 79B on the transmission case door pins 9 With the gearset assembled wrap the clutch nut threads and splines on the mainshaft with electrical tape before slidin
24. ller 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 the 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 L pol FIGURE 15 Ka RW I i Fc 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 automaticallv shift out of reverse the moment power is cut If the bike was running and you were to shift the foot ever out of neutral while the shifting switch is ON and you did not first turn it o
25. n 424 58 Solenoid To Switches Wire Assembly 90 Overall pn 73185 On Off Toggle Shifting Solenoid pn 424 F5R Solenoid To Switches Wire Assembly 90 Overoll pn 420S F5R Shifting Solenoid Assembly Existing Neutral Switch Light Wire pn 426 F5R Solenoids To Neutral Switch Wire Assembly pn 420 F5R Reverse Lockout Solenoid Assembly 1990 1997 All Models 1 Pole Stock Neutral Switch pn A 321 10 Eyelet For 10 Screw TU pn 427 F5R Neutral Switch To Ground Wire Assembly 4 Overall pn 21 438 Neutrol Switch 2 Pole Screw Terminals Normally Open pn 4205 F5R Shifting Solenoid Assembly Existing Neutral Switch Light Wire pn 426 F5R Solenoids To Neutrol Switch Wire Assembly pn 420 FSR Reverse Lockout Solenoid Assembly 1998 2006 All Models 2 Pole Stock Neutral Switch pn A 321 10 Eyelet For 10 Screw TT Existing Neutrol Switch Ground Wire pn 21 438 Neutral Switch 2 Pole Screw Terminals Normally Closed FIGURE 17 PAGE 21 WIRING DIAGRAM V4 4 13 11 BAKER DD6 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 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 15 Following the alpha torque sequence in Figure 15 and using blue thread lock torqu
26. onsequential 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 a BAKER transmission assembly has been disassembled during the warranty period for any reason this limited warranty will no longer apply PAGE 24 TERMS V4 4 13 11 BAKER DD6 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 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 BAKER DRIVETRAIN 9804 E SAGINAW HASLETT MI 48840 On the web WWW bakerdrivetrain com DRIVETRAIN PREMIUM DRIVETRAIN INNOVATIONS FOR AMERIC
27. r PN DD6 2C 1 to gain the room to reach e the snap ring PN 11067A holding 1st gear PN E d DD6 1C 1 in place You need to do this to be able J ip WF to get a press tool around the shaft to press 4th PN DD6 4C 1 and Sth PN DD6 5C 1 gear off See Figure 3 6 Slide the snap ring PN 11067A thrust washer PN 6003B and 1st gear PN DD6 1C 1 towards 3 gear PN DD6 3C 1 See Figure 4 7 Slide the BAKER DD6 RV Press Tool PN 483 DD6RV around the shaft and bolt the halves together Torque the bolts to 20 ft lbs At the same time press off 4th PN DD6 4C 1 and 5 PN DD6 5C 1 gears Remove the rest of the gears from the countershaft at this time 8 With the gears laid out inspect everything gear teeth dog teeth and split cage needle bearings for any cracks excessive wear heat spots or evidence of being run low on oil or without oil FIGURE 4 IF THERE IS ANY DOUBT ABOUT THE INTERGRITY TO RE USE ANY OF THE Se SPLIT CAGE NEEDLE BEARINGS AFTER INSPECTION REPLACE THEM PAGE 10 DISASSEMBLY V4 4 13 11 BAKER DD6 REVERSE 9 Install the provided main drive gear oil seal PN 12035B roller bearing seal PN 12067B and quad seal PN 11165A 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 PN HK2520 GEARSET ASSEME
28. ter Pawl Adjuster 2nd Gear Countershaft Split Cage Needle Bearing Thrust Washer Gearset Snap Ring External Gearset 3rd Gear Counter Shaft 1st Gear C S 3 24 Ratio 1st Gear C S 2 94 Ratio Ath Gear Countershaft oth Gear Countershaft Shift Drum Assembly 14 20 x 1 5 SHCS Black Oxide Washer 10 Plain Shift Fork 4th 5th Mainshaft Shift Fork 3rd Gear Countershaft Shift Fork 2nd Gear Mainshaft Fork Rod Mainshaft 3 24 1st Gear Mainshaft 2 94 1stGear Inner Primarv Race Oil Seal Main Drive Gear Caged Needle Bearing Main Drive Gear Pullev Spacer Oil Seal Roller Bearing Snap Ring Internal Beveled 11 32 Quad Seal Roller Bearing Main Drive Gear Main Drive Gear 6th Gear 2nd Gear Mainshaft 3rd Gear Mainshaft Ath Gear Mainshaft Dog Clutch 4 5 Gear oth Gear Mainshaft Thrust Washer Bearing Door 125 PAGE 9 EXPLODED VIEW DD6 RV BUILDER S KIT LEGEND V4 4 13 11 BAKER DD6 REVERSE DISASSEMBLY j 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 DD6 RV Retro Fit Kit on your BAKER DD6 you do not need to remove your main dri
29. 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 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 switches 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 PN 10C50KCSS Torque to 85 in lbs with blue thread lock 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 crimp Shrink the tubing with a heat gun 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 FIGURE 13 i
30. unger 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 slide the pull 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 up 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 bell 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 PN 31
31. ve 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 DD6 RV gearset install 2 With the gearset still bolted in the transmission case but no shift system slide the gears by hand to lock the transmission in two gears and remove the shaft nuts with a 1 1 16 socket 3 With the gearset out of the motorcycle remove SH gear pnDD6 2M 1 the snap ring PN 11067A and thrust washer PN 6003B to be able to slide 3 gear PN DD6 3M 1 down the mainshaft 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 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 countershaft out of the bearing door Then press the mainshaft out 4 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 Including but not limited too bad threads in the case gouges in the gaskets surfaces residual build up of thread lock and that the case spin freely and smoothly 5 Set the mainshaft aside and start disassembling the countershaft by sliding 3rd gear PN DD6 3C 1 into pa p 2nd gea
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